Tools and materials I propose:
This instrument is inspired by people in Greek prisons before world war two. They used whatever materials they could find in order to make music while locked up. It is also dedicated to their memory. I made mine out of a food tin can, basswood and mahogany.
First I added paint remover on the tin can. This softened the paint. Then I used a wire brush on my drill press to remove the paint.
I then squared a piece of basswood for the neck.
I used my rotary tool and a cutting disc to open up the holes for the neck on the can.
I then did the basic shaping of the neck on the table saw and the bandsaw. I used my tapering jig to cut the 15 degree angle of the neck and headstock joint. I used a couple of dowels to glue the headstock to the neck.
Then I shaped the neck a little bit. Before I glue the fretboard I used a long sanding board to flatten the neck front.
I used my belt sander, files, knives and cabinet scrappers to continue shaping the neck.
Then I started drilling the holes for the tuning pegs. I used a home made centre punch to mark the positions of the holes.
Then I started shaping the neck with a spokeshave and files.
I cut a piece of mahogany on the table saw to make the fretboard. I measured the scale of my instrument which is 34cm from nut to bridge. Then I used a fret calculator to measure to fret positions.
I then cut the fret slots and glued the fret board in place. I used bamboo sticks as pins to prevent the fretboard from sliding around while glue up. These also serve as fret position indicators.
I trimmed the fretboard flush with a block plane and a cabinet scrapper.
It is important that the fret wire fits snuggly but not too snuggly. So you should use a saw that creates the right slot for the fret wire you want to use.
I hammered the frets in place and then added a drop of super glue on each fret end.
I then used files to trim the frets flush.
I masked the fretboard and marked the fret tops. Then with a sanding block I levelled the frets. I sanded until 400grit and then I polished the frets with a buffing wheel on my rotary tool.
I also sanded the fret ends to make them smoother to the touch.
I screwed the neck with the tin in place.
Then I varnished the instrument except for the fretboard. I sanded between coats. I finished the fretboard with mineral oil.
Then I made the bridge and neck. I cut the slots on both pieces at once.
Finally I installed the hooks that keep the strings on place.
And my little prison baglama was ready. It sounds like both bouzouki and banjo in one instrument. I really enjoyed this build. But that was it. See you soon with a new project video.
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