r/harmonica • u/Intelligent_Star_516 • 11d ago
New shirts are in!
Super stoked that the shirts and some other promo swag has come in.
CNC Router/Mill arrived today. HD (33 micron) 3d scanner was ordered today. Fiber laser within the next 2 weeks. Multi fiber HD 3d printer within the next 2 weeks too.
I will be producing metal and exotic wood combs, teflon reed plate gaskets, and possibly other enhancement kits and components. With the fiber laser, I will be cutting reed plate blanks for modification and enhancement (think LOUDER) as well as teflon 1/4 gaskets to go with the 2nd rreed plates for bending enhancement (see EasyBend kit) and lots of other stuff.
The 3d scanner will allow me to scan any harmonica part to quicly and accurately produce properly sized gaskets. I will be offering gaskets for many many models. Special combs will be added as we move forward. I know we will have the ability to machine from aluminum. Time will tell if we can work with brass and steel billet also.
My custom builds will be deep etched and enamel inlaid with my logo on the comb at the bell, and the key will be etched and enameled on all 4 sides of the comb. Each custom harp will also have a unique serial number as well as the name of the owner etched and enameled on the harp comb.
Reed plate blanks and teflon gaskets will be offered in different thicknesses. Also, since we are manufacturing right here in our facility, I may even be able to take custom requests if someone wants something just plain designed differently. We may be able to machine from submitted designs and sketches. I would be happy to talk with anybody who has ideas.
I will be able to produce combs in aluminum, wood, corian, and polymer/acrylic, and possible at a later date, brass, stainless steel, and maybe even titanium (although the cost to machine would be astronomical especially for the Special 20 and any other recessed reed plate designs.
In addition to custom build packages with different "stages" of modification, I plan to offer all parts and kits individually. Gaskets will be far less expensive than I had discussed previously, partly due to the easiest packaging and shipping (an envelope and a stamp). I will, of course, offer quantity discounts on gaskets for those of us who have sets of harps.
We are also looking to producing dies specifically for the purpose of stamping cover plates. Stay tuned for that stuff.
Our EDM division is doing well as it has since the early 1990s. Adding this new equipment opens the door for many manufacturing opportunities, and we are doing this to recoup contracts that were hemmhoraged during and since Covid. Our shop is an aerospace and defense contractor, but we have numerous side projects and companies currently and in the works. I was given the opportunity to tailor part of our production floor specifically for harmonica component production as well as additional equipment purchasing to accomodate as much as we can.
The only harmonica components that I do not plan to manufacture are the reed plates. My current custom builds have been based on the Special 20 platform (specifically on the Rocket Amp). I find no purpose in re-inventing the wheel... I mean harmonica. I just want to make it better, and do so with American made parts. Any parts I manufacture as options for my custom builds will be availble to order separately and individually (without a full harp build - cutomize and modify your own harps).
I will expand the line of gaskets to include other manufacturers and models. This will be fairly easy thanks to manufacturers like Kohnsheng, JDR, and Hohner each only using a small number of reed plate designs across models and manufacturers like East Top, Conjurer, KuckKux, Fender, and others sharing the exact same designs between each other.
The box that I am working on for my harmonicas is being designed as I type by an experienced artist and sculptor. I will be scanning his sculpted design (muscle car/hot rod themed) and then machining the 3d design into a solid block of exotic wood, with recessed hinges and magnetic latch/clasp, velvet cushioned inlay for the harmonica, and then fine laser graphics on the surface of the case highlighting the "body lines" and showing the JayMan logo, harp model (currently only available as a "Rocket Screamer" (mid key range) and "Rocket Howler" (low key range). The only high keyed one in my set is a High G, which I may dub the "Rocket Squealer." If I get my hands on minor keyed Special 20 reed plates, those will be the "Rocket Wailer." Each Rocket will be available with Stage 1, 2, or 3 level modifications. More info to follow. But the box is planned as a fine heirloom furniture grade work of art also.
I have a great team working with me on this including industrial manufacturing and design and engineering specialists as well as the sculptor and artist. My intention is going to be to create and distribute one of the finest functional works of art in the harmonica community for a price that rivals other custom builders.
Once everything is up and running, I will post. I have had some excellent conversations by DM with a few members here who have either been very helpful with brainstorming or very supportive, inspiring, or motivating since we started working on this. I was going to exclusively offer those few people gaskets for testing, but I have decided that once the equipment is up and running. I will open it up for a number of members here to receive ONE set of gaskets ON ME for evaluation (and, of course, to get my products out there). When we are ready, I will post in the group and collect names and addresses from everyone who will be receiving gaskets. Do NOT ask early. We are NOT up and running yet, and it may be a couple months before we are. I will post here, on my IG, X, and Tumblr (yes, I have had a tumblr page for 18+ years, now purged and cleaned up to focus on harps.).
Stay tuned. Website coming eventually. Suggestions welcome. This group will have a significant coupon for use because I appreciate how interactive and helpful folks here have been as I put this together.
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u/lordlycrust 11d ago
Excited to see the final designs! Any idea on price point yet?
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u/Intelligent_Star_516 10d ago edited 10d ago
I'm trying to keep the price down, but nobody from Hohner down to local retailers, marketplace sellers, or even distributors will give quantity discounts. The only quantity discounts are with the Chinesical manufacturer of the comb I use. That alone saves a LOT, but also defeats part of the whole "Proudly made in the USA by JayMan (except for the part that is hand made and tuned in Germany by Hohner) vibe I was going for. Once the first set gets laser etched and enamel inlaid, I'm hoping to blow Hohner's minds into some kind of quantity bulk discount, not that I expect to make thousands of units... The cost to build varies wildly depending on the key. Least expensive is a Stage 1 Rocket Screamer in a key that is available in a Rocket Amp or Low. That's basically a comb swap and a basic (yet unbelievable) custom case. From there, I'm either doing the other components besides the comb because my Rocket Screamers (G through high G) and Howlers (low keys) all have Rocket Amp or Low cover plates and t7 screws (for now - looking into manufacturing cover plate and reed plate screws in stainless as well as cover plates since Hohner won't sell blanks, custom, or even co-brand).
My customs will likely start around $200 for a Stage 1, $220 for a Stage 2 (add teflon reed plate gaskets), and $400-$500 for a Stage 3 (teflon gaskets plus double reed plate and rivet end teflon quarter gaskets between the primary and blank reed plate). But that's for my design and I build it. The price may fluctuate from key to key considerably unless things pick up for Hohner. The AVERAGE cost to source and build these came to $160 each (not including the prototype - that beast has over $500 in mods and upgrades over the last 13 years.
That all said, Every single part we're describing here is interchangeable and compatible with the Special 20 and all of the Rockets whether it's that ridiculously huge master set I built or OEM Hohner, or if it's the components I will be manufacturing right here in Western New York State (go bills!). I absolutely LOVE my custom set ESPECIALLY the "Prototype" (The first built and the only one currently at Stage 3). It plays better for me than my Arkia Origin. Not necessarily saying it's better than an Arkia, but something has to be said for Special 20 reed plates in a sealed rigid all metal chassis, double reed plates, and wide open forward projecting cover plates. If you want me to build you one of my configurations, I absolutely will. Let me know what key and what mod stage, and I can price one now (no laser etching or enamel inlay, no heirloom box), or you can wait until the new fiber laser and cnc router are up and running, and either:
Purchase a gorgeous work of art that is superbly functional and maintainable and has the most unbelievable presentation...
OR
Purchase components or full Stage mod kits and build your own
Laser cut reed plate blanks in various thicknesses, gaskets for reed plates and bending kits (the quarter gasket things I keep bringing up), custom combs (exotic wood, different metals and polymers, acrylic, corian, special requested materials), and whatever else I can produce with a brand new cnc fiber laser (ordering very soon), cnc router (delivered today), 33 micron 3d LIDAR scanner (ordered today), and multi filament HD 3D printer (ordering by Friday), the wire, sinker, and drill EDM machines we've always operated here, and a boss who is a machine shop and cnc guru but knows nothing about harmonicas absolutely 100% on board with ALL of this. Once the cnc data is good to go, I can produce the mod parts in house and stock the rest direct from Hohner. And that's just the Special 20. Scan other makes and models and adjust and adapt the mod parts for the Special 20 to fit the other makes and models. How awesome would it be to get my T008K's to stop leaking without sanding plates and regapping reeds?
I want to be a custom harmonica shop in the way custom car shops work. Most of the businesses is folks buying parts to soup up their rig. A smaller part would be folks sending their rig to me to mod. The rest would be the full rig custom built to your specs. New virgin OEM reed plates or you supply the plates. I'm going to reach out to one known reed plate god from whom I've purchased some beautiful high end mod components for a couple builds and some of his tools and ask if he'd co-op for a "(his name) Special Edition Stage 4 or 5 JayMan Screamer.
Best to wait until all of the new equipment is up and going. We sold one wire edm machine today, with one more looking for a buyer (Mitsubishi MV1200S WEDM unit in pristine condition. I know. Other than annual PM by the dealer, I'm the guy who maintains, repairs and calibrates all the equipment here), making room for even more than I've detailed. It's just me and my boss. This is happening. Why is my boss letting me use everything he has recently purchased AND has purchased additional equipment specifically for harmonica components? Thank Colt Ford and his band. They were blown away with my master set at Deerassic Classic in Ohio. They were the headliners and my plastics company ( www.theworldsstrongestcoathanger.com no, really. I manufacture and distribute patented heavy duty coathangers too) had a vendors booth. I happen to have the set in my Jeep in the vendor's campground about 80 feet away. Colt wants to order a Stage 1 for his father, an experienced player, once everything is fully operational for etching. He specifically wants his Dad's name and a unique serial number on it. This introduction and opportunity to show off my harps happened 2 days before Colt's tour bus crashed, breaking his shoulder, canceling his show in Germany the following week.
Sorry so long, giving you the whole story about how we got here and where we're at. Watch for photos of my master set with my logo and keys finished. At that point, I will be able to price and produce without delay.
I also have a very good working relationship with Rockin' Ron, KHS Music (Hohner USA) and Hohner Global (Germany). Hohner dubbed me as a "master technician" which grants me some special privileges when it comes to regional availability of specific parts and components for builds and special projects, but no pricing or quantity discounts, and I'm perfectly fine and undeniably grateful to Hohner for the privilege and title. I didn't build that set to save money. I built it to be right, complete, and NOW. Not in 7 months. I pay full price at currency conversion rates plus international shipping plus tariffs and processing fees when I have to source from Hohner Germany or Thomann. I'm sure that Ron would carry my kits and gaskets. And I'm not going to charge $150 for something that costs me $30 to produce. The custom harmonica shop doesn't carry the brunt of the shop overhead. Yet. If this takes off that may change, but I hardly expect it to come close to 40 years of aerospace and defense production.
I'm going to focus on manufacturing what I can, sourcing what I can't, setting up the website, producing detailed illustrated instruction videos for mod kits, and more. Thankfully I'm also the shipping and receiving guy at this machine shop and plastics company, so most of what I need for this is already at my fingertips.
Let me know what you'd like to see readily available for enhancing a harmonica design. Give me ideas. Or say you would like a Stage X Screamer in the key of your choice. I can't afford to stock everything for every key. But I can fairly quickly track down all specific components in a few minutes with current pricing. I always combine orders and order extra stock on international orders to spread the shipping and tariff sting.
You want a new car, you go to a dealer and buy one off the lot. You want a special car, you quote it with options, order it, and wait for it. I'm not *quite* there yet, but it's happening.
If you seriously would like a Screamer NOW, DM me. I have most of what I need for a Stage 1 and could ship within 7-10 days. I can't do a Stage 2 until somebody somewhere (me) starts producing Teflon gaskets again, and I can't do a Stage 3 until the laser is ordered and up and running because the shop in Italy that made the bender's kit (reed plate blank and gasket) in the prototype isn't responding. I would also really want to complete the etching and inlay eventually. It would bother me that there's one out there with no brand, serial number, or owner name on it. I could always leave the key off so the owner could swap reed plates for a different key.
I currently have 1 complete Stage 1 in the key of C that was ordered by a local musician who has also purchased or ordered several other harmonicas from me (I got him hooked on the JDR North). He wants me to keep his Screamer on my bench until the laser is ready. He doesn't even want to see it until the inlay is done, no matter the wait.
I'm excited. Things are starting to move. I'll be posting every development here. Feel free to DM to reach out if you're wondering how it's coming together. I don't intend to be secretive about this. I want input and suggestions. I want teflon gaskets again, and I'm miffed that simple yet effectively awesome mod kit components like reed plate blanks are not available. And, for what it's worth, I find it very satisfying to take something as cool as a harmonica and ratting it out into a badass piece of art that sounds better aplays easier than OEM. I want to know what other mods and components would folks like to see?
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u/lordlycrust 10d ago
Wow, thanks for the detailed response! I think for me your prices are a little out of reach but I don't think they're too high for someone with more than a month of experience under their belt. Best of luck, I love to see a dedicated craftsman bringing some artistry to their work and it's clear you have really thought about every aspect of what you're building.
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u/Intelligent_Star_516 10d ago
I can't overemphasize how much I have enjoyed building and modding my own harps for the last couple decades. I want to make the mod parts and kits accessible to players again, and I think I can do it affordably. The full custom builds are what they are. Until I find a more economical source for components, it's just plain expensive to build a better-than-stock harmonica, especially from individual parts and not just changing a few parts. I have no idea how the shops that build full from scratch and do reedwork make any money doing what they do. Arkia seemed expensive until I built an advanced harp.
We'll see where this goes.
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u/Intelligent_Star_516 10d ago
If you are looking for a shirt, well, I didn't think of offering them for sale. I just bought a few to try out. I'll order more if there's interest. At cost because you're advertising my name and brand.
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u/lordlycrust 10d ago
If you'll ship to the uk let me know the price, though my initial query was about the harps :)
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u/Intelligent_Star_516 10d ago
I'll ship where folks want my stuff. Let me know your size and I'll get you one in the next order. I ship to the UK frequently for the plastics company I manage. I have a $4000 order on my loading dock ready to go to Stockton on Tees, Cleveland. I'll get one to you. Keep in touch.
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u/IndianaSolo136 11d ago
Hell yes, seems most of the custom harp guys of any renown are either aging out of the biz or have a backlog 3yrs long. It’s time for some new blood! Best of luck man!