Friday, March 30, 2018

How to make a 2 string musical instrument out of coconut and wood















I made this acoustic instrument using half a coconut and spruce. It is inspired by the Greek small bouzouki we call baglama in our country.

First of all I drilled through the eyes of the coconut and removed the liquid from it’s interior.

I then used a hand saw to cut the coconut in half. I used a cheap chisel to remove the the flesh of the coconut.

I then sanded the hair on my belt sander. To flatten the coconut hemisphere, I used a white marker to mark the lips. I then sanded the piece against a flat sanding block until the marks disappeared. 

I then rounded over the back of the neck with the spokeshave. I used the neck to mark the opening which I shaped using my rotary tool and a sanding drum.

I then shaped the neck to my likeness on my belt sander. 

I cut a thin spruce piece on the bandsaw. I used the bandsaw again to add parallel cuts. These cuts make the piece bendable. I glued it inside the coconut to increase the glueing surface for my instrument’s top.

I then used the bandsaw and my belt sander, to cut and shape the rest of the neck pieces.

I glued the neck with the headstock. I glued the neck on the body and added a screw and shims to get a good fit. I used a sharp chisel to finish the shaping. 

I cut the top on the bandsaw out of a thin spruce piece. I made the sound hole using a forstner bit. I glued a brace under the top. I shaped the brace with a sharp chisel. 

I glued the top on the body. I used the spokeshave, a chisel and a sanding block to make the top flush with the body. 

I then used the bandsaw, a sanding block and a chisel to shape the fretboard. 

I used an online fret calculator to locate the fret positions. The scale of my instrument is 46cm from nut to bridge. I marked the fret positions with a pencil and cut the slots on a miter box. I then glued the fretboard on the neck. I used two bamboo sticks as pins to prevent the fretboard from sliding around while glue up. Those pins also act as fret number locators. 

I used a hacksaw to cut the string holder out of a scrap metal piece. I shaped it with a file and drilled the holes needed on the drill press. 

I used a flush trim saw, to cut the fret pins flush. I sanded with a sanding block. 

I used the spokeshave to finish the shaping of the neck. 

Using wood filler I filled any imperfections on the wood.

I painted the wood that was showing through the sound hole, black. 

I cut the fret wire to size and forced it in place with a clamp. I added a drop of super glue in the side of every fret. I used a file and a sanding block to flush trim all the fret sides. 

I sanded everything with 100 and 220grit. I applied three coats of clear water based varnish. I sanded between coats and used my heat gun to speed up the drying process.

I then cut the nut and bridge on the bandsaw out of a piece of plexiglass. I shaped them with sandpaper.

I assembled all the parts of the instrument and started playing it.

I really like the way it came out!

3 comments:

  1. I want this instrument can u give the freat length chart.please

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  2. Dear sir,I would very much like to make this instrument but apart from the coconut and the top, the dimensions/ measurements for the other parts would make it much eaiser to make.I would much prefer the measurements to be in Inches. Can you help? I'd very much appreciate it. Thank you.

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