How to Make Brass Banjo Parts
The banjo brings out the best of joy in music, past and present. In many circles, the history and construction of the instrument are as much a part of the artistry as playing. If you are making your own banjo or if you would like to dress up an instrument you already play, a touch of brass will add some class. To make your own brass parts you'll need access to power tools. Experience with metal cutting or the courage to experiment will also be required. Use these instructions for making brass banjo brackets to get started.
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Things You'll Need
- 12 inch by 3/8 inch by 5/8 inch brass bar stock
- Measuring tool to 1/16th inch
- Small carpenter square
- Mechanical compass
- Pencil or pen
- Drill press
- Band Saw
- Spindle sander or drill press sanding drum kit
- Tap drill
- 150 grit sand paper
- 6 inch drill press polishing pad
- Brass polish
- 2 inch machine screw
- 3/4 inch by 1 3/4 inch hardwood handle
Instructions
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1
Square the one end of the brass bar stock. Use a small carpenter square to verify that the bar edge is fully square. Use a band saw to trim any excess if necessary.
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2
Mark the brass stock. Place the bar on a flat surface with square edge on the left. Measure 5/8-inch in from the square edge. Use the carpenter square to draw a straight line at the 5/8 inch mark on the wide surface of the bar. Draw another straight line 3/16-inch up from the bottom between the square end and the 5/8-inch line. Draw a third line 3/16-inch in from and parallel to the 5/8-inch line. Use a mechanical compass to connect the 3/16-inch lines with a 7/16-inch arc, using the top corner of the bar stock as the center point.
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3
Drill a bracket clamp hole. Measure and mark a centered dot 3/16-inch in from the square edge on the bottom 3/8-inch stock face. At the mark, drill press a 3/16-inch diameter blind hole 3/8-inch deep into the bar. You will be drilling toward the outside edge of your drawn 7/8-inch arc.
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4
Rough cut the 7/8-inch arc. Use a band saw to carve out the bracket curve. Refine the cut and perfect the curve shape using a 3/4-inch sanding drum on an oscillating vertical spindle sander or drill press. Round the tip of the bracket with a disk sander.
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5
Cut the bracket off of the bar stock. Use a band saw to make a straight cut along your original 5/8-inch line. Round the remaining tip with a disc sander.
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6
Drill and tap the bracket bolt hole. Measure and mark a center dot 1/4-inch from the bottom on the long edge of the bracket. Drill a 5/32-inch diameter hole. Use a number 18 tap drill bit to tap the hole for a number 10 stainless steel machine screw.
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7
Shape the bolt face to fit banjo drum. Use a 3-inch diameter sanding drum on an oscillating upright spindle sander or drill press to sand a slight arc at the bolt entry side of the bracket. This arc will allow the bracket to meet flush with the curve of the banjo drum.
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8
Attach the bracket to a temporary wooden handle. Use a 2-inch machine screw to attach the bolt to a 3/4-inch by 1 3/4-inch block of wood with a lengthwise pre-punched hole. Tighten until stable. This will allow you to turn the bracket safely on sanding drums.
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9
Sand and polish all surfaces until smooth. Use 150-grit sand paper to refine and round all the edges of the bracket. Use the 6-inch polishing pad and brass polish to mirror polish the bracket on a drill press.
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10
Repeat all steps until you have the number of brackets you need. A 12-inch bar will make 16 rough cut brackets.
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Tips & Warnings
Refer to pictures provided on the banjo bracket guide in the references section.
