Build Thread: The Kona Weissenborn Proto-Type

[ozziebluesman]

Hello to you all,

I have been planning this build for about two years and have done my research. The Kona is really a small version of the standard hollow neck weissenborn but with a few differences. It has a 13.5 inch lower bout 9.5 at the upper bout is shorter in length but is 1 " deeper all round than a weissenborn. So it could be said it is the little brother of the weissenborn. The other big difference is it has a solid neck that starts at the 7th fret of a 25" scale. The neck join is similar to a spanish heel but the sides actually glue to the side of the neck itself.

Since organising the Ukulele Course with Joel we have come up with a jig for our students which entails a solera and an outside mould to build the Concert Ukulele with a spanish heel neck joint. I got to thinking this is the way to go for the Kona build so I have built the same jig setup to suit the Kona.

I was lucky enough to be able to obtain a body outline of an original Kona and with that some very important measurements. Another reference is the book by Tom Noe called History and Development of the Hawaiian Steel Guitar. It has lots of good information regard the Weissenborn, the Harp Guitar and the Kona.

This is a proto-type build and I am using some Mahogany for the build and I have a Queensland Maple neck blank.

So I hope you enjoy something a little different and watch me go through some hickups no doubt and I would encourage your comments along the way.

To be continued.....

Cheers

Alan

[ozziebluesman]

Further to the mould today I cut out the body shape from some 18 mm ply and glued it underneath to add some rigidity to the mould. The Kona shape will be used as a sled for the binding later on.

Cheers

Al

[Kim]

Thanks for taking the time to document this and your other builds Alan. For me, and I'm sure many others, build threads represent the single most valuable resource that any craft related internet forum can have.

looking forward to your progressive updates.

Cheers

Kim

[H3ytm@n]

Looking forward to seeing this one Alan.

[ozziebluesman]

A little bit more progress early this morning.

Here are some pictures:

to be continued

[colburge]

I like a good build thread, keep the pics coming, lt looks good so far.


Col

[charangohabsburg]

I never have heard of those Kona Weissenborns, so I googled quickly for "Kona". The first result that popped up was http://konabrewingco.com/

I'm looking forward to your build, it looks quite interesting so far. I also have spotted the book you mentioned (if it is this one, from elderly).

[ozziebluesman]

Yes that is the book Markus.

Here are a few pictures of an original:

Cheers

[charangohabsburg]

Thank you Alan. Probably I'll be about 50$ poorer by the end of this week...

These are gorgeous photos that show some interesting details of the original Kona.

[Nick]

Thanks for posting this build Alan Interesting to see the pictures of the original, they obviously didn't spend a lot of time drilling the tuner holes accurately.

[ozziebluesman]

Nick: Yep some of the woodwork skills where ordinary too! I have a few pictures of inside the box of some of these oldies and they are pretty rough. Anyways, they are legends, I'm not

Here a few pictures of the the neck extension build. The extension has come up good I think but I have made a few mistakes to the side profile and side length that I will point out as we go along. This is a proto-type so it is a learner.

I have come to a stand still as I have no idea what neck join is hiding beneath. I know these guitars are extremely light weight so I am thinking maybe it is a dovetail neck join and a spruce neck block arrangement. Even a simple mortise and tenon could have been used. I also thought it could be similar to a Ukulele and Classical guitar however the sides are glued to the side of the neck extension which differs to the uke and classical. I have also thought that maybe if I leave about 80 mm of the neck extension at the butt end for the side to glue to and take out some waiste to make the neck lighter that might work too! The neck as it is now weighs 477 gram and I need to take off much more material to arrive at final shape.

So I would really appreciate some discussion and help here as I don't think my build needs to be as the origianal Konas's necks where built but strong and light weight.

Cheers

Al

[ozziebluesman]

I have just found out that the neck join of a Kona is a Koa wood block sliding dovetail.

Hmmmmmmmmmmm.

[ozziebluesman]

Not going to worry about a sliding dovetail. I don't think it is necessary and will do similar neck headstock join to a weissenborn only there will be about 50 mm of gluing area for the sides.

Inlayed a simple three rosette and have set out the top brace design. Similar to the weissenborn.

Here are some pictures:

Cheers

[Frenchy]

Interesting project Alan. I've seen once a video of Bob Brozman playing a kona and it sounded gorgeous, as far as I remember.
Keep going !

[timberfreak]

I get the privilege of seeing the progress in the flesh! Keep up the good work Alan!

[Taffy Evans]

I just came across this threed, looks very good Al, you have been busy.

[ozziebluesman]

Thanks Frenchy, Joel and Taffy. Yep I have a number of projects on the go at the moment. Love it

I have made the neck extension and braced the top. It is a similar layout to a weissenborn with the brace closest to the tail block omitted, just two finger braces and a large xmas tree bridge patch. All the braces are 9 mm x 9 mm except the transverse brace which is 13 mm x 13 mm. The back braces have been made and they are also the same size and five back braces instead of six like a weiss. The Xbrace is very close to the sound hole which is 95 mm also the same as the weiss.

This is truly a proto-type so it will be interesting to see how it stands up to open D tuning. I think it will do it easy and I will be very pleased if it has a unique sound of its own...Some more progress pictures for you all and thanks for looking...

Cheers

Alan

[ozziebluesman]

Back has been braced and box closed on this Proto-Type. I am presently surprised at the tap tone on this body. Much bigger sound than I expected. I will let the pictures do the talking.

Cheers

to be continued

[ozziebluesman]

Some more work carried out on the Kona. Box is now closed and binding channel cut top only.

A few more pictures for you all.

to be continued............

[ozziebluesman]

I've been working away at the Kona and I'm very pleased with the response of the top. The Brazilian Mahogany is re-cycled and you only have to lean on it and it cracks so it has been very difficult to work with and I have had to patch a few areas. I have created several cracks to the guitar with clamp pressure myself and I'm usually a very careful builder. The sides where also short and I had to add a piece both sides where the neck joins the 7th fret region at the bottom of the heel. I was just going to do a real rough job on this guitar as it is a prototype and I have no plan to work with but it keeps speaking to me and says I'm going to sound good so I am going to make the extra effort now and finish it off best I can. I did glue on the bridge as I have planned a few wash coats of shellac and then some tru-oil. I wasn't going to bind the top either but I had some Koa there that looked good with the Mahog and though it would add the tie to the suit. Here are a few pictures and there is plenty more sanding to do.

I have learnt few things and taken a mental note to change in the next build and I have already have another neck blank ready with some amendments for the next one. My main issues came working out the neck attachement but I have it sorted now. I also made my first guitar fingerboard too thin like my old Oahu Parlor size lap slide guitar. Don't like that design and much prefer the wider fingerboard like a weissenborn so the next one will be wider at the 7th fret.

To be continued.....

Thanks for looking

[Bob Connor]

Looking good Al. I'm keen to hear your impressions of the sound when you string her up.

Regards

[colburge]

Love it Al, can't wait to see it with a finish on it!

Cheers

Col

[DarwinStrings]

Looking Good Alan, from the pics the side look quite deep but I sort of assume they are less than 120mm, is that correct or are they deeper?

Jim

[Kim]

Coming along very nicely Al, a little squirt of toffee an she'll look a treat

Cheers

Kim

[ozziebluesman]

Bob: Got this one strung up Sunday and I like what I hear. String volume balance is spot on and the tone is bigger than you would think coming from such a small box. Sustain is good and tone is sweet and suits all finger playing. It doesn't have the depth of a weissenborn or that woody, haunting tone a weiss. The Kona does not sustain anything like a good weissenborn does. The bass notes on the Kona are more defined and I would describe the tone as punchy. Overall bass not in the same league as a good weissenborn. So different but very but very interesting instrument. I think Blackwood would make a much better sounding guitar. The wood I used was re-cycled Mahog and very delicate to work with as I managed to crak it several times as it was extremely dry set.

Col and Kim: I have a four session of Shellac applied on it before stringing her up and will go with a tru-oil top up later on.

Jim: The sides are 105 mm at the lower bout and 85 mm at the upper bout. Looks deceiving.

Cheers

Alan