The initial thickness of the Bunya soundboard plate was approximately 3.5 mm, and was very stiff both cross and long grain. The two bookmatched pieces of Bunya were edge sanded and joined at this thickness, before being thinned down to approximately 3.1 mm. At this thickness, the rosette was inlaid and level sanded.
To match the back and sides of this ukulele, a timber ‘Tiger’ Myrtle rosette was made, which also provides a striking contrast to the cream coloured bunya soundboard. The timber rosette was designed to have a black and white purfling either side. The soundboard was routed to a depth of 1 mm, and the ‘Tiger’ Myrtle and black/white purflings installed, before being level sanded. Following this, the soundboard was further thickness sanded down to approximately 2.4 mm, and the soundhole cut out. The Bunya soundboard is still surprisingly stiff at this thickness, and will probably require considerable thinning to produce the desired tap tone, once the instrument is assembled.
To match the back and sides of this ukulele, a timber ‘Tiger’ Myrtle rosette was made, which also provides a striking contrast to the cream coloured bunya soundboard. The timber rosette was designed to have a black and white purfling either side. The soundboard was routed to a depth of 1 mm, and the ‘Tiger’ Myrtle and black/white purflings installed, before being level sanded. Following this, the soundboard was further thickness sanded down to approximately 2.4 mm, and the soundhole cut out. The Bunya soundboard is still surprisingly stiff at this thickness, and will probably require considerable thinning to produce the desired tap tone, once the instrument is assembled.
Bunya Pine soundboard plate, and routed channel for the rosette
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Tasmanian 'Tiger' Myrtle timber rosette
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The Engelmann Spruce braces that are used to reinforce MAKAIO Ukulele soundboards, are specially profiled before installation into a trapezoidal cross sectional shape, that provides a good compromise between stiffness and mass. Once profiled, the braces are sanded so that they conform to the 25 ft diameter dome that will be given to the soundboard by sanding the bottom of the braces on a convex domed/dished work board.
All bracing is fixed to the inside of the soundboard using a go-bar deck, and another concave domed backboard, so that the soundboard takes on the 25 ft domed shape. This in effect pre-tensions the soundboard plate against the force generated by the strings, and allows the soundboard and bracing to be constructed fractionally lighter, improving the ukuleles sound. The first bracing added to the inside of the Bunya soundboard plate was a 1.8 mm thick cross-grain Engelmann Spruce bridge reinforcing patch. This patch will ensure that the force of the fully tensioned strings do not split the soundboard along the grain. The cross braces above and below the soundhole were then added, followed by the soundhole reinforcement plate. Finally, the three fan tone bars were notched to fit over the bridge patch, and were then fixed to the soundboard. The braces and tone bars were then scalloped to further reduce their mass, and increase the flexibility of the soundboard plate.
The bookmatched ‘Tiger’ Myrtle back pieces were first edge sanded and candled so that they fitted perfectly together, and were then joined. Following this, the back plate was thickness sanded to approximately 2.5 mm, and the backstrip inlaid. For this ukulele, a yellow and red marquetry strip was selected for the backstrip, combined with a black/white/black purfling on either side. The inlaid strip was then sanded down flush to the back plate, and then the whole plate was thinned to approximately 2.0 mm.
Three Engelmann Spruce cross braces are used to stiffen the back plates of MAKAIO Tenor Ukuleles. These braces were first profiled to the same trapezoidal cross sectional shape as the soundboard braces, and then sanded to conform to a 15 ft dome. Following this, the braces were fixed to the back using a go-bar deck, and a convex 15 ft radius domed workboard. A 15 ft dome in the back plate of the ukulele will increase the projection, and give the ukulele a larger voice, as well as increasing the strength of the ukulele body.
All bracing is fixed to the inside of the soundboard using a go-bar deck, and another concave domed backboard, so that the soundboard takes on the 25 ft domed shape. This in effect pre-tensions the soundboard plate against the force generated by the strings, and allows the soundboard and bracing to be constructed fractionally lighter, improving the ukuleles sound. The first bracing added to the inside of the Bunya soundboard plate was a 1.8 mm thick cross-grain Engelmann Spruce bridge reinforcing patch. This patch will ensure that the force of the fully tensioned strings do not split the soundboard along the grain. The cross braces above and below the soundhole were then added, followed by the soundhole reinforcement plate. Finally, the three fan tone bars were notched to fit over the bridge patch, and were then fixed to the soundboard. The braces and tone bars were then scalloped to further reduce their mass, and increase the flexibility of the soundboard plate.
The bookmatched ‘Tiger’ Myrtle back pieces were first edge sanded and candled so that they fitted perfectly together, and were then joined. Following this, the back plate was thickness sanded to approximately 2.5 mm, and the backstrip inlaid. For this ukulele, a yellow and red marquetry strip was selected for the backstrip, combined with a black/white/black purfling on either side. The inlaid strip was then sanded down flush to the back plate, and then the whole plate was thinned to approximately 2.0 mm.
Three Engelmann Spruce cross braces are used to stiffen the back plates of MAKAIO Tenor Ukuleles. These braces were first profiled to the same trapezoidal cross sectional shape as the soundboard braces, and then sanded to conform to a 15 ft dome. Following this, the braces were fixed to the back using a go-bar deck, and a convex 15 ft radius domed workboard. A 15 ft dome in the back plate of the ukulele will increase the projection, and give the ukulele a larger voice, as well as increasing the strength of the ukulele body.
'Tiger' Myrtle back, and Bunya Pine soundboard
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After the three cross braces were fixed to the back, cross-grain Engelmann Spruce graft pieces were fixed between each of the braces to reinforce the join between the two halves of the back plate. Preparation of the back plate was completed with the addition of the paper MAKAIO label. Every MAKAIO Ukulele has its own individually produced label to identify the instruments.
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Braced soundboard and back
Soundboard and back
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