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Here are some photographs of things going on in the shop that have been cluttering up my hard drive.

As a dulcimer maker I do a lot of fine, detailed work requiring extreme precision and accuracy.

Perhaps this is why I love using a mallet! Here is my often used mallet resting on top of the form I use for bending dulcimer sides.

Dulcimer Side Bending Jig And A Gentle, Persuasive Mallet

The dampened sides and a flexible heating strip are sandwiched between two long pieces of sheet metal. As heat and moisture soften the sides I gradually apply hand-pressure to the long caul and press the sides to the form. I finalize the pressure and hold everything in place with cam clamps and use the mallet to persuade everything into proper alignment.

I also use the mallet to clamp work to my bench with a holdfast. Here is a picture I took of a holdfast on my bench before photography was invented:

Figure V - a holdfast

 

Planes have a very high opinion of themselves and like to strut their stuff and show off whenever they can. After they worked up a sweat squaring up a big chunk of curly cherry I let them have their moment.

Planes on parade

In our next photo, from left to right, are Romulus the high angle smoothing plane and Remus the toothing plane. Though they come from the same mother they have vastly different approaches to smoothing and flattening wood. Romulus requires a lot of pushing and force but once in motion will smooth almost any wood to a glass-like finish, Remus prefers to score ruts in the wood and show it who is boss. Together they can handle the wildest grain I have yet to  come across.

Two planes that together can handle just about anything - a high angle smoother and a toothing plane

Last but not least I include a photograph of Ms. Agatha Tsatskeh. Ms. Tsatskeh, through the art of interpretive dance, has taught me many things about accuracy, proportion and grace.

Ms. Agatha Tsatskeh demonstrates the ancient principle of the right angle through interpretive dance

 

I am often asked how long it takes me to make a dulcimer. The answer is that I don’t really know. Someday I will figure it out. I do know that I am not making very much per hour!

Here are some of the things that require my time before making a dulcimer.

Digging through my wood stash in the attic

  • Design – It took a lot of time to come up with the specific shape and soundholes for my standard dulcimers. Many drawings were made and several prototype instruments were built to test my ideas. Though the bulk of the design work is complete it is by no means finished; I am constantly making subtle changes to continually improve my instruments.
  • Finding and buying wood – I spend a lot of time visiting sawmills and hardwood dealers searching for the wood that I use. I am very particular about the wood I use so I often come home empty-handed.
  • Resawing – The wood needs to be sawn to the rough dimensions required for dulcimer making. After inspection and sorting the wood gets to age for a while.
  • Selection – After the wood has aged and stabilized I look for the optimal sets of wood for each dulcimer. I usually cover the floor with many backs, tops and sides and look for the ones that will go together best. Tonal, structural and aesthetic consideration goes in to choosing the wood for each dulcimer. Sometimes this process takes considerable time.

At this point  I start doing things that actually look like I am making a dulcimer! Tops and backs are joined, sides are bent, etc. Most of the parts are made as they are needed during construction of each individual dulcimer.

The next three dulcimers

Once the body of the dulcimer is complete I spend lots of time scraping and sanding prior to finishing. Once the finish has cured I install the frets, tuners, nut and bridge and string the dulcimer up. This is always an exciting moment.

I play the dulcimer for several days and break it in. During these first few days the sound of the dulcimer opens up and some small adjustments may need to be made to assure it will have optimal playability and tone.

Added to the time of making the dulcimer is the “down time” as glue dries, finish cures, etc. Though I am not working on the dulcimer while these things take place it does add to the time it takes to make one from start to finish.

Someday I will figure out how much time it actually takes to make a dulcimer from going to the sawmill to having a finished instruments on the bench, though I am not sure I really want to know!

I am glad I enjoy the ride as much as I do!

Studia Instrumentorum Musicae presents some rare resources for those interested in researching historic stringed instruments. I recommend starting with the on-line museum of historic guitars, zithers, and citterns.

The deeper you dig into this site the more treasure you will find.

Bayern, um 1800

Bayern, um 1840

Hummel Instruction Book

Sign.: "J. Wallis / LONDON" (Händlerzettel, gedruckt)

Sign.: "Repariert / Hans Müller Leipzig / 1959" (Bleistift, auf Furnierstreifen Decke innen)

Richard Jacob "Weißgerber" Markneukirchen 1920

Musicians have nightmares about flying with their instruments. Though a mountain dulcimer will almost always fit in overhead storage the instrument is technically too long to be considered carry-on baggage by many airlines.

Flying with a dulcimer

I rarely have  trouble carrying-on a dulcimer. Here are a few things I have learned over the years:

I fly with my dulcimer in a gigbag with a shoulder strap.

A gigbag takes up less room than a hard case and looks smaller and more compact when noticed by flight crews. A shoulder strap lets me carry the dulcimer on my back and leaves my hands free to show my ticket when boarding. Since I am carrying my dulcimer with ease it sometimes goes unnoticed. I rarely have trouble bringing a small backpack and dulcimer on board.

If possible I reserve a seat towards the back of the plane.

Usually the rear seats board earlier and many overhead bins are still empty and available.  The flight crews are usually less concerned about this odd-shaped piece of musical luggage taking up space while there is still plenty to go around.

If told my dulcimer will not fit overhead I politely explain that it has always fit in the past.

The flight crew is doing their job. They are people. Be nice to them!

If the flight crew tags my dulcimer to be checked as cargo while boarding a smaller plane I discreetly take the tag off and put it in my pocket .

I have only  done this a few times. I was able to carry on my dulcimer with no problem.

There have been a few times when all the overhead compartments were full or an airline employee’s purpose in life has been to keep me from bringing  my dulcimer on the plane. In 30 years of flying with a dulcimer I have faced these scenarios 3 or 4 times. In these situations the only option was to have my dulcimer hand-placed in cargo. Theoretically this means it is carefully placed in cargo and carefully removed and given to me as I leave the plane.

When this has happened my dulcimer survived. I survived too but the flight was anything but relaxing!

CD Baby is the firm that handles my online CD and MP3 download sales. They are currently donating $1.00 for each CD or album download towards Haitian Relief Efforts.

This offer applies not only to  my recordings but to thousands of independently produced albums.

From CD Baby:

CD Baby will donate $1 toward Haitian earthquake relief for every CD and album download sold.

The earthquake and its aftermath in Haiti have touched all of our lives. Many in the CD Baby family have already contributed as individuals, but we wanted to do more to help the victims of the horrible earthquake tragedy. By selling your music on CD Baby, you can help raise funds towards those affected by the disaster.

Starting on Monday, January 25th and continuing through February 7th, we will donate $1 of our cut from every CD sale through our website, and $1 from every download sale over $8.99 on our site, to the American Red Cross and to Mercy Corps, a Portland-based relief organization with a large presence in Haiti. The donation will be taken from CD Baby’s fee, and will not affect the amount of money our independent artists earn when you buy their music.

Clicking on the CD covers will take you to my albums at CD Baby.


Doug Berch "Songs From My Past"




Doug Berch "The Sadness Of Common Objects"






This post is inspired by a router bit that slipped in the chuck while working on a curly claro walnut and Adirondack spruce dulcimer this afternoon.

When I saw the bit was tearing through the side of the dulcimer a sense of calm came over me. I turned off the router. I looked at the gaping maw in the side of the dulcimer-to-be and thought of ways I could make an invisible repair, or perhaps use the opportunity to do something creative in the place where colorful, curly figure would have been plentiful.

But reason prevailed. The dulcimer was not even half built. I should just quit and start another.

And there was the cherry and spruce dulcimer that had been hanging around the shop for a few years that I knew I’d never let out the door. It was an experimental design that did not live anywhere near up to my expectations.

My solution as to what to do next was inspired by the work of my friend Michael C. Allen of Cloud Nine Musical Instruments.

Dulcimer Quality Control

Visible is the cherry and spruce dulcimer. The curly claro walnut and Adirondack spruce dulcimer served as kindling.

It is nice to have a fire on a cold day. I have no marshmallows to toast in the fireplace so I guess I will go back to the shop and get back to work.

 

Handy Shop Tips

Some odds and ends I’ve gathered from here and there.

Some of these ideas make sense. Some make some sense. Some I’m just not sure about.

I really should be asleep by now.

I was going to drive to Columbus, Ohio this evening and continue  in the morning to Bardstown, Kentucky for the festival.

It snowed all day and into the night. Reason caught up with me. I decided it would be best to  drive straight to the festival in the morning. It is a seven hour drive, maybe more if there is snow.

I need to be there by 5:00 PM or so.

I think I can I know I can I think I can I know I can…Choo Choo!  (Anyone get the reference?)

Someone once asked me if I became a musician so I would not have to work!

The festival should be a lot of fun. I’ll have a few dulcimers for sale while I am there too.

Come by if you can!

KMW Winter Dulcimer Weekend

Well, mainly the big ones.

I have become very frustrated with my beautiful old Stanley/Bailey jointing planes.

Dear Stanley/Bailey jointer plane, Why won't you stay flat and true? Is it something I said?

They feel great in the hand, have enough weight to add heft to my planing and they are beautiful to behold.

The problem is that I can not get the soles to stay flat. I have spent many hours getting the soles on both a #7 (22 inches) and #8 (24 inches) flat only to find that something as simple as taking out the blade for sharpening and replacing it can cause the sole to become concave.

Many woodworkers think a plane need not be dead flat. I agree, but only for certain types of work. When I am leveling a fretboard or jointing the back  or soundboard for a dulcimer a reasonably flat, long plane makes the job go very quick and easy.

I am aware that these trusty old metal planes were not intended for work requiring this much precision. This is why I thoroughly researched how to tune-up these planes for fine woodworking. I made sure the frogs were well seated. I flattened the sole with the blade installed so the plane would be under the tension as if it were in use. I added thick after-market blades. I chanted mystical incantations, etc.

This has worked well on the smaller planes but the big ones just don’t stay flat.

If anyone has suggestions as to how I could get these big planes flat and get them to stay that way please let me know!

There are currently made metal jointer planes that are made for fine work. They are expensive but friends of mine who have them say they are worth ever penny. I may go that route someday but I hope to resolve the problem by either getting these old Stanley’s to work or switching to wooden jointer planes.

My experience with wooden planes has been very positive. They are easy to keep flat and I like the feel of wood against wood when planing.

A set of wooden planes. Will you be my friend?

I use several wooden smoothing planes, both with high angles and 45° and love the results. I also fixed up an old wooden jack plane that is very comfortable to use. I have an old 22 inch wooden jointer plane that works well but is a bit too bulky for some of the finer work I do. I also would prefer the blade to be at 55 ° ( as I would on several  of my metal planes) so I would not have to sharpen using back-bevels.

I am thinking I will make wooden  high-angle jointer plane. With instruments to finish and gigs to play I probably will not be able to get around it until  next month. It should be fun!

Bringer of Joy

Many of my friends know that I have chosen two possible epitaphs for my tombstone that I feel succinctly sum up certain aspects of my life:

  • “No One Said There Would Be Math”
  • “He Played The Hammered Dulcimer But Never Made A Christmas Album”

In light of the second possibility I would like to share that I love this time of year and there is a warm place in my heart for things seasonal and festive.  On the other hand I do tire of the rampant commercialization of  this beautiful  time of year.

But enough of my rants and raves.

Here is my holiday gift to you all!

Boing To The World! – Arranged and Performed by Doug Berch 

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A performance for an appreciative audience

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