Doug Berch

Dulcimer Maker And Musician

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What’s On The Bench – June 14th, 2019

This chromatic dulcimer in walnut will have a zircote fingerboard and spruce soundboard.

On the bench is a chromatic dulcimer having reinforcements glued in to lock the ends of the braces into the sides. The reinforcements add strength to the joinery and makes the inside of the dulcimer look neat. The reinforcements are shy and happy to be hiding under the clamps where they can’t be seen.

While the glue was drying I carved the ramp that goes from behind the bridge (shown by a pencil line) to the end of the dulcimer. I start the ramp by sawing off the waste and continue shaping it with rasps, files, and scrapers. When I placed the fingerboard on the body to double check the length it asked me to take the above photo. Unlike the reinforcements mentioned earlier, the fingerboard is not shy.

I’m currently working on two bespoke chromatic dulcimers. The one above will be in walnut, spruce, and zircote, the other is in oak, spruce, Spanish cedar, and zircote.

I am regularly receiving requests to make fully chromatic dulcimers and they seem to be becoming popular.

Further Adventures In Hand Planing

Planing dulcimer fretboards to proper dimensions.

I once wrote about developing the skills to accurately plane parts to proper dimension. I have recently been making some changes to my planing technique to accommodate the capabilities and lack of capabilities of my body.

Some physical issues make it challenging to do as much planing as I have done in the past. I thought I might have to get a thickness planer and jointer to do some of the work I enjoy doing by hand. After further thought I chose to reconsider my approach to using hand planes.

Until recently I got rid of lumps and bumps, hills and valley, Satan’s minions, and anything else in the way of a smooth, square, flat surface by using a jointer plane early in the process. Using that wonderful, big, long, and heavy plane repeatedly does not make some of my body parts happy anymore so now I take out the lumps and bumps, hills and valley, Satan’s minions, and anything else in the way of a smooth, square, flat surface by relying more on smaller planes and then finish up with the jointer plane.

Either approach has long been in use by woodworkers and luthiers but the latter works better for me now.

I also recently acquired a skewed low-angle block plane with a fence that makes getting the sides of the fingerboard assembly square to fingerboard much easier. I used to leave my fingerboards a little wide so I could true them with the jointer plane and have enough wood to remove in order to get the surface both straight and square; this usually involved some trial and error and the extra wood provided a margin for error. Now I mill my fingerboards a little narrower and after getting the sides straight with the jointer plane the skewed low-angle block plane with a fence lets me square the surface using light, delicate cuts.

All is well in the tiny, happy part of the world that is my workshop.

Preparing A Dulcimer Fingerboard For Receiving The Frets

Custom dulcimer with ebony fingerboard by Doug Berch

On the bench today is a custom chromatic dulcimer with an ebony fingerboard. The spruce soundboard has been stained and lightly distressed to add some character. I’m a character and so are my dulcimers. So it goes.

Many dulcimer makers fret the fingerboard early in the construction process. It is much easier to install the frets when the fingerboard is separate from the dulcimer; one can hammer or press the frets in without any thought of possibly crushing the dulcimer beneath them!

I know several dulcimer makers who get good results fretting the fingerboard before gluing it to the dulcimer but I prefer fretting the fingerboard after assembling the dulcimer and applying the finish.

Experience has shown me that applying the finish to a dulcimer sometimes results in slight movement of the soundboard and fingerboard. By fretting after applying the finish I can level and/or add relief to the fingerboard and have it come out exactly as I prefer it to be.

I use a scraper and a few sanding blocks to prepare the fingerboard for fretting. The scraps of wood lying on the dulcimer prevent bad, scary things from happening to the soundboard while working on the fingerboard.

The movement of the fingerboard and the correction I am talking about is measured in thousandths of an inch. As a player I find these small increments can make a surprising difference in how much I enjoy playing a dulcimer.

Fretting towards the end of a build requires more work but I am often told my dulcimers are very comfortable and easy to play and this is a part of how I make them that way.

What’s On The Bench – 11/20/2017

Slotting an ebony dulcimer fingerboard.

On my calendar was recovery from back surgery this past week but there was a change of plans; a dental issue came up and surgery was postponed. Instead I am taking antibiotics and will have minor dental surgery in a week or so. The back surgery will probably be within a month or so after that.

Let it not be said that I don’t know how to have a good time!

I’m a firm believer that what is happening is happening and what is not happening is not happening so I am rolling with it.

In the meantime I am up to my usual tricks and getting some work done in the shop.

In the photograph above is a simple setup for cutting fret slots. The miter box is made from scraps of MDF and the depth stop on the saw is a strip of wood held in place with three colorful spring clamps.  The wooden cam clamps hold the miter box to the work-board and holds the fretboard in place while sawing.

This  low-tech setup works remarkably well.

I have templates for fret patterns I commonly use. The templates eliminate calculating and measuring out the fret positions.

This fingerboard is for a custom chromatic dulcimer with a scale length I have not used before; 743 centimeters! That is a very long string length but is what the person who will be playing this dulcimer prefers.

Since I didn’t have a template for this scale length I had to calculate the fret positions and lay them out on the fingerboard. Fortunately, there is software that does the math. In the 1970’s I had to spend a long time with a calculator to work out fret positions. The constant often used to calculate an equal tempered fretboard, 17.81715385, is still permanently installed in my memory.

I laid out the fret positions using a very accurate ruler, machinist’s square, sharp knife, and patience. I triple checked the measurements before sawing the slots.

Sawing the slots with the miter box was the fun part.

 

 

You Say Dulcimer Fretboard, I Say Dulcimer Fingerboard

Adventures of a dulcimer builderA dulcimer doesn’t have a neck but it has something under the fingerboard that sort of serves as a neck. Calling it a neck doesn’t really make sense but when the dulcimer has a fingerboard on top of the object that shall not be called a neck then appropriate terminology becomes even more confusing.

For no particular reason I refer to the lower portion of the assembly as the fretboard and call the fingerboard overlay the fingerboard. When describing a fretboard with a fingerboard on it I refer to the assembled unit as a fretboard.

In the photograph above I’m gluing the fretboard assembly to a dulcimer soundboard.

The soundboard is clamped to a flat workboard. Two clamps come in from the sides holding scraps of wood that rest against the sides of the fretboard at either end. This makes it easy to accurately place the fretboard in the right spot and helps prevent it from moving while I apply the clamps.

I use an old trick to clamp the full length of the fretboard down using only two clamps. A long, warped piece of wood is used as a clamping caul with the concave side facing down along the length of the fretboard.  When I clamp both ends down the flattening of the warped wood exerts pressure along the entire length of the fretboard.

You can follow more of my my action-packed adventures as a dulcimer maker by following me on Instagram.

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Doug Berch & Dulcimer Makers