Monthly Archives: September 2019

3 posts

New Viola – part 5 (closing the box, fitting the neck)

Instrument Making

This week, it’s time to finish the viola “in the white” or do everything before the varnish is applied.

The linings, which are 2mm think strips of spruce are glued to the inside of the ribs. This gives more surface area when gluing the plates to the ribs.
Gluing the back to the ribs.
The mould had now been removed, and I’m gluing the linings to the face-side of the ribs.
Fitting the bass bar perfectly to the top takes hours of work. The fit has to be precise or else any number of issues may arise.
Gluing the box shut. This always feels like a big step being accomplished.
Taking a quick victory lap.
The neck has been morticed into the box.
The neck needs to be carved into a playable shape. This step is very important, since the neck is the main point of contact between player and instrument.
Neck rounded.
Just a bit of fun- Gillian’s viola on the left, the new viola on the right.

View the next article here: New Viola – part 6 (varnish, set-up)

New Viola – part 4 (the scroll)

Instrument Making

This past week, I’ve been working hard on the scroll for this new viola!

I use the bandsaw to cut out the outline of the scroll. I like to paste a picture of the model on the wood to give me an accurate guide.
Cutting out the first turn of the scroll.
First turn has been cut, and the area around the pegbox also removed.
Cutting the second turn. Here, we’re running into a bit of trouble – a sap pocket (the brown section).
The sap pocket runs deep and is inconveniently located.
Nothing to be done except replace that side of the scroll.
Luckily, there was plenty of spare wood when cutting the outline. I was able to easily find a piece big enough and with very similar grain to replace that side.
The scroll is rough-carved at this point. Now is when I like to clean out the pegbox. I start by drilling holes to the correct depth, then going at it with a small chisel.
Cleaned up and relaxing with Gillian’s cranes.
The replacement is visible, but not too obvious. I think it adds a bit of character.

View the next article here: New Viola – part 5 (closing the box, fitting the neck)

New Viola – Part 3 (rough thicknessing, f-holes)

Instrument Making

After the purfling is glued, I can clean up the edges and finish the arching of the top. After that, I carve out the inside and cut out the f-holes. Pictures below.

I’ve cleaned up the arching here to more-or-less its final shape. The edges are left rough still until the body is glued up.
I use my drill press to give me guide depths so I know when to stop carving. These are all leaving 5mm of material, which gives me plenty of margin for error.
Next step is to rough out the inside to those depth holes.
Once the inside is cleared out to around 5mm, I can start on the f-holes. I used a hole-saw specially made for this purpose this time around (thanks Mom and Dad for the birthday gift!)
I use a coping saw to get the general shape of the holes, and refine the shape with a very sharp knife.
This is after a bit more clean-up. They’re starting to get close!
View from the inside at this stage.
Here comes the fun (but tedious) part. I use a thumb plane to gradually decrease the thickness of the top to get it just where I want it. The caliper is an invaluable tool at this step, though I also gently flex the plate to get a feel for what’s going on mechanically at each step.

View the next article here: New Viola – part 4 (the scroll)