Clavichord Day 14 - More Tortoiseshell Prep

Today, we continued prep for the tortoiseshell design we've planned. Having applied a second coat of primer (this time using a roller rather than a brush!), the first chore was sanding the primer smooth.



That done, it was time for the yellow undercoat. The idea is to build up the paint in transparent layers to create the look of real tortoiseshell. Yellow, being the lightest and brightest color we will use, goes on first and underneath all the darker and richer layers.

We started with the lid:


The fallboard and even the tiny toolbox lid got covered.


Then, it was on to the case.



Since this all needs to dry before we can continue (once again), it is worth pointing out one step I forgot to photograph from a couple of days ago. The lid, when opened, will lean back at an angle, but it will not fall all the way back. This is because a string will connect from the instrument itself to the lid. The string will tie to two screw eyes -- one in the lid, and one in the hitchpin block. Look closely below, and you can find the holes I drilled.


If all goes well, tomorrow we should be able to get to the heart of the tortoiseshell.

Clavichord Day 5 - Guide Rack, Belly Rail, Cheek Liner, Tool Box Back and Hitchpin Rails

Today was a long day, and the basic case construction is now complete! So, how did we get here?

First, we had to trim and adjust the guide to fit. The guide rack goes right on top of the backrail, and has slots carved into it. These will keep the keys moving up and down, but not side to side.

Here, the guide rack is clamped in place.


A look at the whole case, with the guide rack glued in on top of the back rail. Notice the vertical slots carved in.


Next, the belly rails and cheek liner were glued in. These pieces, forming an angled and multi-sided face, will eventually make the left-most ledge for the soundboard to rest on. Here's a look at the cheek liner clamped to the right cheek, with the standing belly rail (with mouse hole) already glued to the bottom.


What's a day without some glue cleanup?


A look at the right side of the case. The front, rear and cheek liners, the wrestplank, and belly rails--all making the trapezoidal ledge for the soundboard to sit on later.


Next, the small detail of the little piece of cherry glued to the balance rail and hitchpin block, forming the rear wall of the "tool box." One day, there will be the tuning hammer inside and a fancy lid on top!


The last big project was to get the hitchpin rails done (both treble and bass rails). This meant trimming to size, marking for the pin holes, and gluing them into place.
After trimming, we had to get the rails underneath the plan drawing so we could mark for each little pin hole (later to have hitch pins inside). After securing the rail under the drawing, we had to dimple the wood on each little X, using the awl to gouge through the drawing and into the rail.

Here's a look at the short bass rail after all the pin holes were marked.


Finally, gluing in the rails. First the bass rail, right on the hitchpin block.


Then the longer treble rail, perpendicular to the bass rail, and glued onto the guide rack.


At last! Here is the instrument at the end of Day 5. The major case work has been completed, and everything is fitting just right so far. Next comes the soundboard!

Clavichord Day 1 - Wrestplank, Hitchpin Block, and Rim Assembly

Today, we began construction on the clavichord! After some sanding and the like, the first step was to put the rim together with some corner clamps and lasso ties.

Then, we made sure it was nice and square.


Next, the hitchpin block on the left and the wrestplank on the right were glued to the sides of the case with clamps to keep them in place.


Finally, the entire rim was glued together. Here's the instrument at the end of Day 1:


We also started preparations for attaching the case to the bottom, and we're having to use a lot of clamps to make sure it stays square. Hope to get to that ASAP!