A range of steps were completed to progress the ukulele from separate back, soundboard, sides and neck, to the completed or “boxed” body. At the start of this process, the components of the ukulele included the back and soundboard with shaped bracing, the neck with Spanish style heel block and carved heel, and the thicknessed timber for the sides. The steps that have been undertaken form the constructed body for this ukulele include:
1. Cutting the side pieces to the required profile, so that they follow the domed shape at the soundboard and backboard edges
MAKAIO Ukuleles are produced to have a 15 ft radius domed back and a 20 ft radius domed soundboard. The doming of the ukulele soundboard pre-stresses the soundboard to resist string tension, allowing the soundboard to be built lighter than flat topped instruments. The tighter curve for the ukulele back gives the instrument greater projection and helps make the ukulele body more comfortable to hold and play. To allow the soundboard and back to truly follow the domed shape, the side width of the instrument varies around the instrument perimeter. To allow for this, the sides are cut to a pre-determined profile prior to bending, increasing the ease of forming the ukulele body.
2. Bending the side pieces
Following initial profiling the ukulele sides are bent to shape using a specially made steam bending form. The heat and moisture applied to the timber side pieces allows the timber to become pliable, and the pieces are pulled into shape on the bending form.
1. Cutting the side pieces to the required profile, so that they follow the domed shape at the soundboard and backboard edges
MAKAIO Ukuleles are produced to have a 15 ft radius domed back and a 20 ft radius domed soundboard. The doming of the ukulele soundboard pre-stresses the soundboard to resist string tension, allowing the soundboard to be built lighter than flat topped instruments. The tighter curve for the ukulele back gives the instrument greater projection and helps make the ukulele body more comfortable to hold and play. To allow the soundboard and back to truly follow the domed shape, the side width of the instrument varies around the instrument perimeter. To allow for this, the sides are cut to a pre-determined profile prior to bending, increasing the ease of forming the ukulele body.
2. Bending the side pieces
Following initial profiling the ukulele sides are bent to shape using a specially made steam bending form. The heat and moisture applied to the timber side pieces allows the timber to become pliable, and the pieces are pulled into shape on the bending form.
Bent Tasmanian "Tiger" Myrtle side pieces
3. Joining the soundboard to the neck table at the heel block
The first step in forming the ukulele body is to join the soundboard to the neck, by fixing the soundboard into the recess that was previously cut into the neck block.
4. Shaping and joining the tail block to the soundboard
To reinforce the tail area of the ukulele, a solid timber block is placed between the soundboard and backboard at the tail of the instrument. This block also allows a strong joint at the tail of the body between the two side pieces. The tail block is first shaped to form the curved body profile, and has the slope sanded on to the top and bottom of the block to conform to the domed shape of the soundboard and back. The soundboard and neck are then placed on a specially made ukulele construction jig, and the tail block is glued into place on the soundboard.
The first step in forming the ukulele body is to join the soundboard to the neck, by fixing the soundboard into the recess that was previously cut into the neck block.
4. Shaping and joining the tail block to the soundboard
To reinforce the tail area of the ukulele, a solid timber block is placed between the soundboard and backboard at the tail of the instrument. This block also allows a strong joint at the tail of the body between the two side pieces. The tail block is first shaped to form the curved body profile, and has the slope sanded on to the top and bottom of the block to conform to the domed shape of the soundboard and back. The soundboard and neck are then placed on a specially made ukulele construction jig, and the tail block is glued into place on the soundboard.
Neck and tail block fixed to soundboard
5. Cutting the bent sides to length and joining to the soundboard
The bent side pieces are cut to the exact required length, and are dry fitted to the soundboard and neck. Once final adjustments are made, the sides are glued to the soundboard, neck, and tail block.
Fitting side pieces to soundboard and into neck block
6. Fixing the kerfed lining between the sides and the soundboard, and the sides and back
To reinforce the joint between the soundboard and sides and the back and sides, solid timber kerfed liner strips are sanded to shape and glued into place. This maintains the strength of the ukulele body, even once the perimeter of the instrument is cut to allow timber binding to be fitted.
Completed body with kerfed lining installed
7. Closing the ukulele body by joining the back plate
Once the kerfed lining is fitted, the interior of the body is final sanded, and the ukulele back plate is fitted to the body sides. During this step, the cross braces on the back plate are cut to the correct length, and the kerfed liner strips in the body are notched to allow the cross braces to fit neatly. The back plate is then glued and clamped to the sides, and the body allowed to dry overnight.
8. Trimming the back and soundboard to be flush to the sides
The final step in forming the ukulele body is to trim the excess material from the soundboard and back plates to form a neat flush joint with the instrument sides.
Once the kerfed lining is fitted, the interior of the body is final sanded, and the ukulele back plate is fitted to the body sides. During this step, the cross braces on the back plate are cut to the correct length, and the kerfed liner strips in the body are notched to allow the cross braces to fit neatly. The back plate is then glued and clamped to the sides, and the body allowed to dry overnight.
8. Trimming the back and soundboard to be flush to the sides
The final step in forming the ukulele body is to trim the excess material from the soundboard and back plates to form a neat flush joint with the instrument sides.
Completed body front - Queensland Bunya Pine soundboard
Completed body back - Tasmanian "Tiger" Myrtle
Bunya Pine soundboard with Tasmanian "Tiger" Myrtle rosette
The beautiful Bunya soundboard gives this ukulele a nice contrasting appearance against the "Tiger" Myrtle back and sides, and the timbers combine to provide a strong but unique tap tone. The ukulele body will now be further refined by selectively thinning areas of soundboard and back to improve the voice of the ukulele by allowing the soundboard and back to resonate more freely.
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