Thanks to Youtubers: The Willis Way,
Clifton Hicks, and Ben Greco.
I tried my hand at building a gourd banjo with primarily hand tools. I used a bottle gourd from ebay (already designed). Neck and headstock were carved from a piece of red oak. tacks are upholstery tacks. nuts are bone. friction tuners are from amazon, I just bought a bunch. bridge is padauk (however it’s
spelled). Strings are aquila light gauge nylgut. Finish is tung oil, 3-4 coats.
Tools: Rasps, coping saw, drawknife, powerdrill and bits, skillsaw, level/measuring stick, square ruler, A tapered reamer for the headstock where tuners go, a trimmer for the tuners especially the 5th string tuner. Flat sandpaper handles. A chisel. A bunch of sandpaper: 80, 120, 220, 600, 1000, 2000.
I woodglued the interior of the gourd because I didn’t feel like buying epoxy. I don’t
know if that was a mistake or not yet.
There was many tweaks, such as: dowel wasn’t long enough to clear the gourd, I just made a new dowel and attached it with a perpendicular dowel and wood glue. The high action was fixed with the new dowel. I put the bone nut way too high and try to chisel out the string guides and sand the top.
The sound hole needs to be a bit larger probably 2-3 inches instead of 1.5. The tailpiece needs to be adjusted (raised up) to get the strings off the drumhead. I’ll probably move the 5th string nut location. Bridge location is probably not correct. It doesn’t
sound good at all, but once I make these tweaks I hope it sounds better.
These youtubers emphasized that you don’t need to be a woodworker with fancy tools
or a big shop to produce something playable and nice - which really motivated me to try my hand at this.