the construction and repair of balalaikas - …...the construction and repair of balalaikas 4...

TheConstructionAndRepairOfBalalaikasИзготовлениеиРемонтЩипковыхМузыкальныхИнструментов

TheConstructionandRepairofBalalaikas

2

Thisisatranslationofpp.19-22,114-152oftheoriginalRussianbookwhichis©Издательство«Легкаяпромышленностьибытовоеобслуживание»,1988

Изготовлениеиремонтщипковыхмузыкальныхинструментов,Авторы:Н.А.Комаров,С.Н.Федюнин

Годиздания:1988,Издательство:М.Легпромбытиздат,ISBN:5—7088—0195—6,Страниц:272

ОдобреноУченымсоветомГосударственногокомитетаСССРпопрофессионально-техническомуобразованиювкачествеучебникадлясреднихпрофессионально-техническихучилищ

Constructionandrepairofstringedmusicalinstruments,Authors:N.A.Komarov,S.N.Fedyunin

Year:1988,Publisher:M.Legprombytizdat,ISBN:5-7088-0195-6,Pages:272

ApprovedbytheAcademicCounciloftheUSSRStateCommitteeforVocationalandTechnicalEducationasatextbookforsecondaryvocational-technicalschools

©1988"LightIndustryAndConsumerServices"Publishers-Legprombytizdat

TranslatedfromtheRussianbyBostonBalalaikaWorkshopasaservicetotheworld-widebalalaikacommunity.Allrightsarereservedbythepublisher.Thismaterialmaynotbereproduced,displayed,modifiedordistributedwithouttheexpresspriorwrittenpermissionofthecopyrightholder.


3

TechnologicalSequenceofBasicOperations

Manufacturingstringedmusicalinstrumentsinthemodernenterpriseisacomplexmanufacturingprocess,employingpreciseengineeringcalculationsperformedonnumerousmachinesbyalargenumberofskilledworkers.Atthesametime,theproductionofmusicalinstrumentsinasmallworkshop,andincottageindustries,isbasicallythesameprocessasinthelargeenterprise.Thedifferenceisthatthebuilder,increatingmusicalinstruments,solvesthetechnicaldifficultieshimself,assometimesbothimplementeranddesigner.Hemustclearlyimplementtheentireinstrumentmanufacturingprocess,correctlyplanningthecourseoftechnologicalprocessesofmanufacturingindividualparts,assemblies,andfinishingoftheinstruments.

Intheexampleofproducingabalalaika-primawewillconsidertheprocessesinindustrialandhomeworkshopsituations.Firstofall,weshoulddefinethemainstagesofproduction.

Theproductionprocessisunderstoodtobeaseriesofcollaborativehumanactionsandthemeansofproduction,resultingfromrawmaterials,billetsandcomponentpartstoproduceasinglepurposeitemofthequalityrequired.Thus,themanufacturingprocessincludesthesupplyofbusinessmaterials,energysupply,thedesignofnewproductsandimprovementstopreviouslymadeproducts,transportationproblems,andmuchmore,andmostimportantly-themainproductionitself.

Themanufacturingprocessisacompletepartofthemainproduction,whichyieldschangesinshape,size,position,status,andpropertiesofmaterials,orbillets,orserialconnectionofcomponentpartsinaccordancewiththetechnicaldocumentation.

Themanufacturingprocessofamusicalinstrumentinvolvestheproductionofitsparts,theirassembly,andfinalprocessingoftheentireinstrument.

Themanufacturingprocessofeachpartofamusicalinstrumentisseparatedintoanumberofstages.Theydifferfromeachotherbythenatureofprocessing(e.g.,cutting,gluing,lacquering,etc.),orthedifferentgoalssetatthisstage(e.g.,cutting,machining,etc.).

Themanufactureofmusicalinstrumentsisconcernedmainlywithwood,forwhich,asisknown,ischaracterizedbyspecifichumidityproblems.Therefore,initialdryingandfinaldryingofwood,beforewegotowork,isoneofthefirststagesoftheprocessofanytimbercompany.Byitself,thedryingofthewoodisalsoconsideredanindependentprocess.Thesecondstageoftheprocess,afterdrying,iscuttingofthewood.Resonantspruceplanksarecutoutatathicknessof4-5mmforinstrumentsoundboardsand9-10mmforbalalaikabasesandsoforth.Valuablebuildingwoodsforbalalaikastaves,guitarsidesandotherpartsaresawnoutorplanedonspecialmachinesinto3.5-4mmthickbillets.


4

Mechanicalmachiningofworkpiecesistypicallydoneintwostages.Thefirststage-theprocessingofroughbillets-istogivethemthecorrectgeometry.Forthismachiningprocessallfoursidesareworkedincrosssectionandinlength.Theresultisafinishedworkpiece(billet).Inthesecondstagethefinishedpieceisworkedindetail,contoursarecutinthebillet,thenecessaryholesaredrilled,sandingdone,etc.Forexample,theheadstockintheformofplatesiscutwithapatternfromthefinishedbilletandthepocketunderthetuningmachinesisprepared.Theseoperationsarethesecondstageofthemanufacturingprocessofmakingtheheadstock.

Assemblyofthebalalaikafromthefinishedpartsisdividedintoseveralstages.Thefirstofthemistheassemblyofpartsintoassemblyunits.Thus,severalboardsarecollectedfortheinstrument’ssoundboard,3-4partsarecollectedtomaketheneck,etc.Assemblyunitsarepre-treated(thesoundboardisplaned,theneckisglued,etc.),andthentheygointotheassemblyoftheentireinstrument.Someassemblyunits,suchasfretwire,areinstalledonlyonthefinishedproduct.

Themainstagesoftheprocessareshownintheexampleofmakingabalalaika,asshowninthediagram(Fig.0.1).Thenextstageintheprocessofmanufacturingthebalalaika,afterthedryingstageistheroughwork,andthenthefinishingofthebodydetails:neck,base,bodystavesandbasewedges,pinblock,linings,etc.Thebodyismadefromthepartslisted(I).Thesoundboardisgluedupfromseveralresonantboards(7).Manufacturingandprocessingthesoundboard,thebracesbeinggluedtoit,formingthesoundhole-allofthisrepresentstheprocessofmanufacturingthesoundboard.Theresultofthisprocessisanassemblyunit–thebalalaikasoundboard,whichmakesuptheoverallprocess.Theprocessofgluingthesoundboardtothebodyiscalled‘zakubrovka’(II).Joiningthesoundboardtothebodyiscompletedwiththeinstallationofthebindings(thindarkcoloredstrips)andthedecorativecorners(III).Theheadstock,aftertheroughandfinishmachiningstagesisgluedtotheneck(IV).Finishingthetopwiththeapplicationoflacquerandthenpolishing(V)isthenextstageoftheprocessofmanufacturingabalalaika.Makingandgluingonthefingerboard(VI),shapingandlevelingthefrets(VII),makingthebridge,thepickguardandgluingittoinstrument(VIII)arecrucialfinalstagesofthemanufacturingprocess.Next,theinstrumententersthefinishingprocess.Thelaststageisinstallingthetuningmachines,thestrings,stretchingthestringsandtestingofthefinishedinstrument.

Manufacturingprocessesforindividualassemblyunits(neckblanks,soundboards,headstocks,etc.)areindependentoftheoverallprocessofbuildinginstruments,sotheycanbedoneinparallelandinadvance,thatis,partscanbeproducedforfutureuse.Inpractice,thisisoftendonebythecottage-industrybuilder(ormaster).

Moststagesoftheprocessofmanufacturingmusicalinstrumentsincludethemachiningofwood.Inadditiontoexperienceandtheabilitytomastermodernwoodworkingtools,youneedtounderstandaboutwoodasaconstructionmaterial,aboutthedryingofwood,itsdecoration,etc.


5

Fig.0.1.Manufacturingprocessofbalalaikaconstruction:

I–bodyassembly:1–neck;2–base;3–bodystaves;4–basewedges;5–linings;6–pinblockcover;II–Bodytopinstalled:7–balalaikasoundboard;III–Bodywithbindingsinstalled:8–binding;9–corners;IV–Gluingtheheadstock:10–headstock;V–Finishedsoundboard;VI–Gluingthefingerboard:11-fingerboard;VII–Installingfrets:12–fretwire;VIII–Installingthepickguard:13–bridge;14–pickguard


6

BasicConstructionParametersandInstrumentStructure

Balalaika:-ARussianfolkstringedmusicalinstrument,designedforbothsoloplayandplayinginastringorchestra.

Thebalalaikaisakindofhistoricalbodypattern,whichisbasedonatriangularsoundboard(Fig.1).Thebodyitselfisaconicalsurfaceconsistingof5-10stavesandaflatbase.Theinstrumentneckhasatraditionalformforpluckedinstrumentswithtuningmachines,whichcanbeeitherclosedoropenbacked.

Thebalalaikahasthreestrings,twoofwhicharesynthetic(usuallynylon),andthethird,metal.

Thebalalaika-primaisusedforsoloplaying,andtheorchestralinstrumentsaresecond(sekunda),alto,bassandcontrabass(Table1).Table1.Basicparameters,mm

Index Piccolo Prima Sekunda Alto Bass Contra-bass Vibrating Length of String L 400-415 435-450 475-490 490-535 750-780 1100-1180 Instrument Length А 620-630 675-685 745-765 800-820 1120-1160 1600-1700 Body Length В 250-265 275-290 310-325 325-355 500-535 790-820 Body Width at Base С 385-400 420-435 485-500 510-525 700-735 1060-1250 Body Height at Base Н 90-100 110-120 130-145 145-155 200-220 335-360 Fingerboard width at Nut а 26-28 28-30 30-31 30-31 33-36 36-40 Fingerboard width at 12th Fret b 31-33 34-36 36-38 36-38 40-43 48-50 Fingerboard thickness at 1st Fret m 15-16 16-17 19-20 19-20 28-31 36-40 Fingerboard thickness at 12th Fret k 17-18 19-20 23-24 23-24 34-36 50-52 Soundboard thickness h 2 2 2,5 2,5 3 4,5 Fret where neck meets body 18 16 15 15 15 13 Number of frets n 21-24 19-24 15 15 18 16-17

Mass-producedmusicalinstrumentsusuallyadheretothemeasurementsshownunderthepartdescriptionandproductspecifications.Instrumentsofthehighestquality,theso-called"custom"ones,areconstructedinspecializedworkshopsorbymaster,home-basedbuilders(i.e.thecottage-industry).Therefore,inmanyofthesizes,instrumentswillhaveratherwidetolerances.


7

Fig.1.Six-staveBalalaika:1–Tuningmachines(closed);2–headstock;3–uppernut;4–neck;5–fingerboard;6–neckblock;7–braces;8–linings;9–soundboard;10–bridge;11–base;12–lowernut;13–pinblock;14–basewedges;15–basebinding;16,17,18–staves;19–neckheel;20–tuningmachinecover;21–strings;22–frets;23–fretmarkers;24–soundboardbinding;25–pickguard;26–rosette;27–corners;28–string(bridge)pins


8

PrimaBalalaikaistuned:

Second(Sekunda)Balalaikaistuned:

AltoBalalaikaistunedandsoundsoneoctavelowerthanwritten:

BassBalalaikaistuned:

BassBalalaikaistunedandsoundsoneoctavelowerthanwritten:


9

MakingtheNeckBillet

Theneckismadefromhardwood:beech,walnut,mahogany,rosewood,ebony,etc.

Generallytheheavierthewoodspecies,thebettertheneckturnsout.Neckpreparationshouldstartwithwell-seasonedwood.

Thebilletfortheprimabalalaikaneckisa300x60x25mmblock.Afterprocessing,theneck(1)(Fig.2)hasasmalldecreaseincross-section,from17downto15mmattheend.Theheel(3)isattachedtotheneckwithhideglueandalamination(2),whichiscutoutofbirchorwalnutveneertoathicknessof0.5-0.8mm.Ifthematerialoftheheelisthesameasthatoftheneck,thelaminationcanbeomitted(ifdesired).Arrangementofthelaminationlayersintheformsshownhereisdesirable,asseeninFig.2.

Fig.2.MakingtheNeckBillet:1–neck;2–lamination;3–heel;4–setof3sheetsofveneer

Thebilletisoftendecoratedasfollows:beingcutalongthecenter-lineoftheneckwiththeheelgluedandthehalvesreversed.Itisjointedwithaplanebeforebeingglued.Asetofthreesheetsofveneer(4)areinsertedbetweenthehalvesoftheneck:twodarkandonelight,ortwolightandonedark.Itmaybelimitedtoonesheetofveneerasdesired.Thecoloroftheveneerselecteddependsonthecoloroftheneckwood.


10

Fig.3.Layoutandsketchofneckblock:а–layoutofheelundertheneckblock:1-6–cutswithfinetoothedsaw;б–sketchoftheneckblock;1,5-cheeks;2-contouroftheouterpartoftheneckblock;3–contouroftheinnerpartoftheneckblock;4,7–cuts;6–upperpartoftheneckblock;в–outercontouroftheneckblock

Aftertheglued-upheadblockisdry,layitoutforfurtherprocessingasshowninFig.3.Atadistanceof17mmfromtheedgeoftheheeldrawthelineonacontour.Accordingtothislineuseafinetoothsawtomakecutsfrom1thru6atthedepthsshowninFig.3a.Totheleftandrightoftheheel,place16x16x50mmmaplescraps(pads)(1)and(5)(Figure3.б).Thelayersaredirectedalongthestaves.Thetopoftheneckblock(6)isachieved,cuttingofftheheeltoadepthof3mm.Workingtheneckblocktocontours(2)and(3)isdonewithachisel,strictlymaintainingthetheoutercontour(Fig.3c).Trynottocuttheinnercontour(3).Cut(4)and(7)(seeFig.3.б)toadepthof7mmtocompletethepre-processingoftheneckblock.

Thebilletfortheheadstockispreferablymadefromthesamematerialastheneck.Ifthisisnotpossible,thenglueabillet80x240mmmadeofhardwood(beech,rosewood,etc.)4-5mmthicktothemaplebillet,planeddownto15x80x240mm.Youcanuseslicedveneerofthesamethickness.Afterthegluehasbonded,planedownuntilyoureachathicknessof15mm.Thethicknessofthe


11

bondedveneershouldnotbelessthan2mm.Onthenon-facesideoftheheadaredrawnthecenterlineandthemaindimensions,asshowninFig.4,markingouttheshapeofthehead.Markingwitha06.2mmbit,drillapilotholeat(1),establishingthefirstpegholeforthetuningmachinesandthenfindtheothertwocenters.Theholesshouldtouchthestringsoftheguidelinesat(2).Afterthisinsertthetuningmachinepegsintotheholesuntiltheystopanddrawanoutlineofthebaseasshownat(3).Thetuningmachineslotdepthiscutfirstwithanelectricdrill,andthencleanedupwithanarrowchisel.Clutchingtheworkpiecewithaholdfast(clamp),theheadstockiscutoutaroundits

outline.TherecessforthemetalgearsiscuttothedepthshownatЬ.Thedepthofcutisselectedandcustomizedforeachtypeofmechanism.Tuningmachinesshouldsittightinthesocketandberecessedflushwiththeheadstock.Thebuilderisfreetoformahead,butthemainconsiderationsareeaseofuse,eleganceofthedesignandreliability.

Fig.4.Headstockbilletlayout:1–pilothole,2–linesforstringlayout,3–channelundertuningmachines,4–layoutlines


12

ConstructingtheBodyParts

Astavebilletshouldbe2.5mmthickafterfinishplaning.Manyhardwoodsaresuitablefortheconstructionofstaves,butmostcraftsmenprefermaple.Inaddition,thisspecieshasgoodvisualandacousticproperties.Anydiscrepancyinthefigureofthewoodisparticularlynoticeableinthetwocentralstaves,andthisshouldbeconsideredwhenselectingandmatchingasetofstaves.

Fig.5.StavesizesforPrimaBalalaika

Astavesetismadefromsixpieces.Oneextrastaveiskeptinreserve,justincaseastavebreaks.Onthebilletsdrawtheoutlineofthepattern(Fig.5)andworkthecontourswithachiselandaplane.Particularattentionispaidtotheprecisepreparationofthestavesonthesides,towhichaveneerstripwillbeglued.Thesamesideofthestaveisangled:forthefirststave20°,forthesecond15°andforthethirdleft10°.Thethirdrightstaveisworkedonlywithachisel(orsmallplane),leavingareserve(extra)of3mm.

Veneerstripsaregluedtothelateralsidesofthestaveswiththebevels,whosecolordependsonthecolorofthestavewood.Generally,thestripsarecutfromdyedbirchveneerof0.8mmandawidthof3.5-4mm.Glueisappliedtothelateralsideofthestaveandveneerstrip.Theveneerstripispressedin


13

withthenoseofametalhammer.Iftheveneerstripdoesnotadhere,itcanbetiedinwiththreadorstring.

Fig.6.Dimensionsofthebaseforthebalalaika-prima

Thebaseismadeoftwoglued-uporonewhole10mmthickfirbillet(Fig.6).Itispermittedtohavesolidintergrown(included)knotsupto10mmandlocatednocloserthan20mmtotheedgeofthebase.Thecontourofthebaseismadefromatemplate.Eachofthesixfaceshasasmallbeveledangleofabout10°,whichiscutatthedesirededge.

Theloweredgealsohasanapproximate20°bevel,butintheoppositedirection.Thebaseshouldbewelldriedandthoroughlyplaned.Allcornersofthecontourofthebaseshouldbecheckedforsymmetryrelativetothecentralaxis.


14

AssemblingtheBalalaikaontheTemplateanditsSubsequentProcessing

Theassemblytemplate(1)hasapairofclampswhichholdtheneckbillet(2)withthepreparedneckblock(Fig.7).Keepadistanceof280mmfromthebeginningendoftheneckblocktotheedgeofthebase(3),alsotowhichtwoclampsareattachedtothetemplate.Whenyouinstalltheneckandbasepaycloseattentiontothealignmentoftheaxesofthesecuredpartswiththecentralaxisofthetemplate.

Theassemblybeginswiththepreparationofthefirstleftstave(1)(Fig.8).Tosimplifythefiguretheclampsarenotshown.

Fig.7.Preparationofthetemplateforbalalaikaassembly:1–template;2–neckbillet;3–base

Fig.8.Fitthefirstleftstave:1–thefirstleftstave;2–veneerstripforfirstleftstave;3–facetsoftheneckblock;4–neckblock;5–base;6–facetsofthebase;7–pencillineoftemporarynailjoints


15

Thenarrowendofthestaveisattachedattheappropriatefacetoftheneckblock(4).Forasnugfittotheendputachamferonthestave.Fromthewidthofthestave,customizeitsothattheveneerstrip(2)thatisbondedtothefirststavepassesbeyondthelength(3)oftheneckblockfacet.Havingattachedthestavetothefacet,press(bend)thestavetotheedgeofthebase.Theveneerstripmustalsopassthroughthefacetsofthebase(6).Eliminateanygapthatmightappearbetweentheendofthestaveandtheneckblockwithachisel.Ensurethatthestaveisfirmlyfixedagainsttheneckblock,cleaningupwitharaspasneeded.Youwanttomaintainthecontouroftheinnerpartoftheneckblock.Thisoperationisrepeatedinfittingtheotherstaves.Thenadjusttheedgeofthebasebeneaththesurfaceoftheadjacentstavewiththerasp.Thus,thereliabilityoftheinstallationofthefirststavedependsonquiteasnugfitofthesurfaceofthestavetothefaceoftheneckblockandtheedgeofthebase.Inthis,thestaveiscurved(orbent)andthefittingiscarriedout,holdingitfirmlywithyourlefthand.Havingmadesureofagoodfit,runtwopencillineswherethestavecontactsthebase.Turnthestaveover(Fig.9)andwithanawlpiercefour1to1.5mmholesthroughthestave.Theangleoftheholeshouldbe45°.Afterthat,proceedtogluing.

Fig.9.Piercingholesfortemporarynailattachment1–pencillinefortemporarynailholes;2–awl;3–holesforthenails

Hideglueisappliedtothepartofthestave(Fig.10),whichcomesincontactwiththeneckblock(4),andonthefacetoftheneckblock.Thestaveisattachedtothefacet.Holdthestavewithtwo‘shoe’nails(tacks)throughapadmadeofbirchveneer.Itprotectsthestavefromnailscratches.Driveanadditionalnail(5)intothetemplate.Itmaintainstheconnectiontotheneckblock.Duringthebuildingprocessyoushouldavoidmakinganydentsandscratchesonthebodystaves.Thenglueisappliedtothestavebetweenthedarkenedpencillines(7)(seeFigs.8&9),aswellasontheedgeofthebase.Pressthestaveagainstthebasewiththelefthand,andwiththerighthand(seeFigure9)insertfourtacksintothepredrilledholesinthestaveanddrivethemthroughthestaveintothebase.Checkthecorrectnessoftheclampingalongthegluedjoint.


16

Thefirstrightstaveisfittedandinstalledinthesamesequenceasthefirstleftstavewas.Atthesametimepayattentiontothestrictsymmetryofthefirstpairofstaves.

Thenarrowendofthesecondleftstaveistrimmed(shaved)withachiseltothesizeofthefacetontheneckblock.Chamfertheendandinstallthesecondstaveoverlappingthefirst,joiningitwiththeveneerstripontothefacetoftheneckblockandbase.Pressingthestavewiththelefthand,withtherighthanddrawapencillinealongtheinsideedgeofthebodyfromtheedgeofthefirststave.Removingthesecondstave,cutwithachiselalongthelinejustdrawn,leavingamarginof1mmextra.Thelastmillimetercanberemovedwithafinishingplane.Testfitthestavetodetermineanyerrorandrepeatthesamefittingprocesswiththeplane.Iftheveneerstriponthestavehasdescendedfromthefaceoftheneckblockorbase,i.e.thestavehasnarrowed,itistrimmedalongthelengthfromthesideofthenarrowpart.Afterthisthestaveissetanditswidthrestored.Tofitthesecondandthirdstavesontheirlateralsidesmakesmalladjustmentstothebevelforatightfitwiththeneighboringstaves.Whenattachingthesecondandthirdstaves,glueisappliedtotheveneerstripoftheadjoiningstavewiththeexceptionoftheneckblockandthebase.

Tosecurethebondbetweenthefirstandsecondstaves,andthesecondandthird,usebrackets.Bracketssuitableforthispurposecanbemadeofsoftcopperwirewithadiameterof1.5-2mm(Fig.11).Crookingtheendofthewire(1)aroundthefirstleftstave(2),pullthewireandbenditaroundtheotherendoftheleftedgeofthesecondstave(3).Itshouldnotmakeadeepdentinthesecondveneerstripofthestave(4).Thebottompartofthewirecanbemovedinthedirectionofthebasetostrengthenthetie.

Fig.10.Fixingthefirstleftstavetotheneckblock:1–thefirstleftstave;2–installationoftheveneerstrip;3–twotacks;4–neckblock;5–additionaltacks

Fig.11.Installationofthebracketfortyingfirstandsecondstaves:1–annealedcopperwire;2–thefirstleftstave;3–thesecondleftstave;4–secondleftveneerstrip


17

Thesecondrightstaveisinstalledinthesamesequenceasthesecondleft.

Whenyouinstallthethirdleftstaveassembly,thesamesequenceisfollowed.Itshouldbenotedthattheveneerstripofthecentralstaveshouldstrictlyfollowtheaxisoftheneckblockandbase,whenpositioningitinthefittingprocess.Beforeattachingthethirdleftstavethecontouroftheribistransferredtothethirdrightstave.

Preparethethirdstavebasedonthefinalcontourononeside.Fromtheothersideextendapencillineinsidethebody,aswasdonewhenprocessingthesecondstave.Thepreparedthirdrightstaveinthemiddleofitslengthshouldbeonemillimeterwiderthanthespacebetweenthethirdleftandthesecondrightstaves.Afterapplyingtheglueonallthecontactsurfacesthelaststaveisfixedtotheneckblock.Then,pushingfrominsidethebodywiththelefthand,usingtherighthandwithalittleeffortthelaststaveispressedintoplace.Afterfixingthestavetothebasewiththenails,placeaclipofcopperwireacrosstheentirebody.

Wipetheliquidgluefrominsidethedriedbalalaikabodyalongtheseamsofthestaves.Thisiseasiertodowiththerightindexfinger.Excessadhesivecanberemovedwithaclothdippedinhotwater.

Fig.12Layoutliningsfromtemplatea–layoutonliningboard;1–spruceboard;2–cutlines;3–controlline;b–alayouttemplateforlinings


18

Ifchipsorcracksdevelopduringtheprocessofassemblytotheneckblockandbasethenfillthemwithshavingsandhideglue.

Afterdrying,theseamsbetweenthestavesontheinsidearethengluedwithdensefabric(suchascalico).Smearhideglueononesideof1cmstripsofcloth,andpressthemintotheseamsofthestaves.Theendsofthestripsshouldoverlaptheneckblockandbasebyonecentimeter.Attheendofthisoperation,itisrecommendedtouseaclothsoakedinglueanddrawitalongtheinteriorseamswithyourthumbnail.

Whilewaitingforthebodytodry(about2-3hours),starttopreparethelinings.Forthis,asprucebillet(1)(Figure12a),quarter-sawnwithnoknots,ismarkedwithlines(2)andsawnwithanarrowbowsaw.Foreasyorientationatthetopofacurvedpart,drawapencilline(3).ThetemplatefortheliningscanbemadebasedonthemeasurementsinFigure12,b.Cutalongthelinessothatthepencillinesremaintotheleftofthecutandisnotcrossed,i.e.“leavetheline”.

Theprocessingsequenceoftherightliningisnext.Theliningoftheoutersurfaceoftheworkpieceiscutwithachisel(supportingitontheworkbench)sothatthesurfacemirrorstheinsideofthefirststave.Thisisdifficulttoperformthefirsttime,asitrequirespracticeandagoodeye.Theliningshouldbecut(maintained)ascloseaspossibletothepencilline.Across-sectionoftheinstalledandclampedlining(1)isshowninFig.13

Apocket,whichwasmadeintheneckblockforthelining,cuttingbitbybit,wascompletedearlier.Asocketforthelininginthebaseismadealongthecross-sectioncontouratadepthof1to1.5mm.

Fig.13Installationoflinings1–rightlining;2–firststave;3–notchingtheliningintothebase;4–skirtingthenestneckblock;5–clamp


19

Thepreparedlining,tightlyseatedinitssockets,isamodelforproducingthesecondlining.Theyaremirrorimages.

Thesurfaceoftheliningisworkedwitharasp,joiningtothestavewithtacks,dabbingwithhideglueandputtingintoplace.Clampingoftheglued-upliningsisaccomplishedwiththreeclamps.(SeeFig.13)

Afterdrying,theliningsinsidethebodyandtheentireinteriorsurfacearesandedandcoveredwithoneortwolayersofnitrocelluloselacquer.

Securethebodyanduseafinetoothsawtocuttheproturdingendsofthestavesflushwiththebase.

Thestrengtheningofthebodycomesfromcreatinga"domed"deck.Thereisagreatamounttensioninthebalalaikafromthestringsstretchedoverthetop.Itispossiblethatthatamountofforcecanbendorbucklethetop.Thisisatfirst,ugly,andsecond,itcanhardlybeexpectedtoimprovethesoundwithsuchadeformedtop.WorkalongthebodywithaplaneandraspcorrectingaccordingtothediagramshowninFigure14.

Fig.14.Bodystrengtheningdiagram

Withapencil,markoutthelocationsofthewedgesonthepreviouslyplanedbase,.Todothis,connecttheverticesofthebasewiththecenter(A)(Figure15a).Thebasewedgesaremadefromthesamematerialasthebodystaves,selectingfromathicknessof2.5-3mm.Planewedge№1perpendiculartotheplate,adjustingittothemeasurementsonthebase.Ensurethecorrectness,cuttingthelengthof


20

thewedgeflushalongtheglueseambetweentheedgeofthebaseandthebodystave.Thesurfaceofthebaseistreatedwitharasporscraperplanelikethereversesideofastave.Thewedgecoatedwithglueispressedintoplaceandsecuredwithafewtacks.Fitasecondwedgesimilarlytothefirst.Whenattachingthefirstandsecondwedges,installaveneerstripofthesamecolorasinthebody.Theveneerstripisdippedingluebeforeinstalling.Removetheexcessgluewiththefingersofthelefthandputtingitbackintothegluepot.Pressthesecondwedgefrombothsides,asshowninFig.15.б.Thefifthandsixthwedgesarealsosecuredfrombothsides(Fig.15,в).Intheareaofthepoint(A),wherethetopsofthewedgesconverge,cleanupthisareawithaplaneorknifeandsealitwithglue.

Fig.15.Asetofwedgesonthebasea–firstwedgeinstallation;1–wedge№1;2–tack;б–settingsecondwedge;1–veneerbetweenthefirsttwostaves;в–settingthesixthstave;1–siteforpinblockcover


21

Fig.16.Gluingthebindingsontothebase:1-6–bindingstrips;7–bodystave;8–base;9–basewedge

Ifthebasewedgesareaccuratelyfit,thentherewillbeapoint,narrowandstraightbetweentheendsofthewedgesandtheendsofthebodystaves.Ifthewedgesofthebasearenotequidistant(about3mm)mirroringthebodycontour,thenthedefectcanbecorrectedwithafinetoothsaw,withwhichthewedgesaresawnlengthwise.

Itisrecommendedthatthetwo-sidedangleformedbytheendsofthebasewedges(9)andthebodystaves(7)(Fig.16)becleanedafewtimeswithaheavyquadrangularknurledmetalfile.Thisis,sotospeak,asocketunderthefacebinding.

Bindingsarecustomfitinthisorder:1,2,3,4,5and6.Thebindingendsarecut"likeamustache"withachiselsupportedonthebench.Gluethebindingsinthisorder:1,6,2,5,4and3.Thethirdisthe"castle"thatis,customized,whenalltheothersareglued.Thegluedbindingsaretiedinwithropeaccordingtothediagramshown(seeFig.16).Forgreaterclarity,thebasecontourisdistorted.Forabetterfitofthebindingoneofitsfacesismadeoutofsquare.

Fig.17.Arrangementofthepinblockcoveronthebase

Usingablockplane,thedriedbindingisplanedflushwiththewedgesfromthebaseside,andfromthesideofthebodystavesthisoperationisperformedwithametalfile.Anycracksanddefectsdiscoveredarefilledwithamixofsawdustwiththeappropriatecolorofhideglue.Afterthoroughlydrying,thebaseisplanedandpolishedwithemerypaper.

Apinblockcoverisinlaidintothebase(Fig.17).Atfirstthepinblockcover,previouslycutfrom1.5mmthickdyedbirchveneer,isplaceduponthebasewedgesandthecontoursareoutlinedwithasharpenedpencil.Theresultingoutlineiscutoutwithacutteratadepthof1-1.2mmandthenroutedout.Thepinblockcoverisglued(withhideglue)andsetinwithahammer.Werecommendedthatthe


22

shapeofthepinblockcoverbedonetothedimensionsshowninfigure17.Thepinblockcoverformorshapemaybeofadifferentdesign.

PreparationoftheSoundboardandGluingittotheBody

Resonantspruceboardswiththicknessof4mmandalengthof300mmcanserveasbilletsforthecreationofabalalaikatop.Thewidthoftheboardsisusuallynolessthan60-70mm,althoughinprincipalthewidthdoesnotmatter.Muchmoreimportantistofindbilletswithannualringsrunningwidth-wise(quartersawn)fromtreesgrowninshade.Theseparameters,toacertainextent,enhancethehomogeneityofthepotentialtopanditsacousticproperties.

Boardsarefirstselectedandthenplaneddown.Thisallowsusnotonlytoidentifythestructureofthematerial,butalsotodeterminethedirectionofplaning,whichisshownbyarrows(Fig.18).Therearetwovariantsofselectionforabalalaikatop-thecentralfugue(matchedplatesorbook-matched)orbyacentralboard.Matchedsoundingboardsarethenlabeledandtheedgescarefullyjointed.

Glueuptheresonantboardswithcaseinglue,butinrecentyearspeoplehaveincreasinglyusedPVA(plasticized)forthesepurposes.Plates(1)(Fig.19)aresmearedonbothsideedgesandclamped(2).Clampingplatestoeachotherissupportedwithwedges(3).Withadditionalwedges,youcanadjustplatesrelativetoeachotherinheight.

Fig.18Variationsoftopproduction1–soundboardwithacentralfugue;2–soundboardwiththecentralplate;3–arrowshowsplaningdirection

Fig.19.Gluingresonantplates.1–resonantplates;2–clamps;3–wedgesfortightening;4–additionalwedges

Thedriedtopisplanedonbothsides,topandback,bringingitdowntoathicknessof2.5mm.Clampingsupportisproducedbyathickwoodenslab(asheetplywoodissuitableforthispurpose).Screwheadsprotruding1.5-2mmoutofthewoodensurfacecanserveas(planing)stops.Before


23

planing,thedirectiontotakeshavingsisdeterminedbythepreviouslyestablishedsetofarrows.Afterplaningitisrecommendedtosandthetop.

Thepreparedtopisjoinedtothebalalaikabody,strictlymaintainingthecenterline,andfollowingthebodycontour(1)(Fig.20).Cutthetopalongthiscontour(withaoverlappingmarginof5mm)usingajigsaw,knifeorafinetoothsaw.

Havingdefinedthefaceside,specifythecenterlineand,indenting110mmfromtheedgeofthetop,markthecenterofthefuturesoundhole.Focusingonthecenter,settherosette.AnacceptablerosetteforthebalalaikaisshowninFig.20.б.Thetechniqueforfittingtherosetteisthesameastheexamplediscussedforfittingthepinblockcover.Aftertherosetteisdry,itisscrapedflushandanydefectsfoundarefilledwithsawdustandhideglue.Buildingthetoprequiresahighdegreeofaccuracy,sincethethicknessof2-2.5mmmakesitveryfragile.

Bracesforthebalalaikatop,aswellasforothermusicalinstrumentsaremadefromresonantspruce.Aradialcutboard(Figure21)ismarkedoutonitsendin10mmincrements.Atthesemarksuseanax(orfroe)(SeeFig.21a),sothatthegapformedbysplittingthewoodreachesadepthof40-50mm.Theninsertabladeintotheslit(Fig.21b)andcleaveabracefromthebillet.Thisisdonetoensurethatcleavageoccursstrictlyinthetangentialplane.Harvestedbraces(Fig.21c)havedimensionsof10x20x300mm.Thesizeof10mmisadjustedwithaplaneto4mm.Thenoneofthetwonarrowedgesisplaned(Fig.21d)onanarcofaspecialpattern,allowingthecreationofthedomedinstrumenttop.(SeealsoFig.14.)Thistemplateiseasytomakefromanordinarywoodenruler.Withapieceofstringononesideofawoodenrulerdrawanarcataradiusof1820mm.Thederivedarclineisthetemplate.(SeeFig.23)


24

Fig.20Placementoftherosetteonthebalalaikatopa–positionoftherosetteonthetop;1–contourofthebalalaikabody;2–centerofthesoundhole,3–centerlineofthetop,б–dimensionsoftherosettefortheprimabalalaika

Fig.21Preparingthebracesa–notchingax;б–cuttingknife;в–measurementsforpreparingprimabalalaikabraces;г–brace,planedbasedontemplate

Fig.22Gluingthebraces1–top,2–brace,3–clamp;4–clampingcaul


25

Bracesaregluedwithhideglueinaparticularsequence.Thinpencillinesmarkoutthepositionofthefuturebraces(2)ontheinsideofthetop(Fig.22).Beginbyattachingbracenumber1.Glueisappliedtothearchededgeofthebraceandthebraceisputinitsplace.Fromthefacesideofthetop(1)installaclampingcaulofspruce,sectioned25x5mmandplaceaclamp(3).Forbestclampperformancecuttheedgeofthebracesbeforegluing"likeamustache."Thisshouldnotleavegapsbetweenthegluedbraceandthetop.Anydefectiseliminatedwithsmallwedgesinsertedbetweentheclampingcaulandthetop.Forbestperformance,slightlymoistenthewedgesbeforeinstallingthem.

Afterdrying,thegluedbracesareshapedwithachiseltogettotheappropriatesizeswhichareshowninFig.23.Sharpedgesonthebracesshouldbesandedsmooth.Theinsideofthepreparedtopiscoveredwith1-2layersofnitrocelluloselacquer,leavinga15mmwidebarestripalongthecontour(edge)ofthetop.

Thetopistightlyfixedtothebodyalongtheaxisandnotchesaremarkedonthebindingswithapenciltodeterminethelocationforthesocketsforthebracestofitinto.Socketsarecut,usingachisel,knifeandfinetoothhandsaw.Socketsareestablishedatadepthof4mm,butitisbesttofiteachbraceindividually.Thebalalaikatopisthenputontothebodytoensurethatthebracesfitsnuglyintheirsockets.Thentrimthetopalongthecontourofthebodyleavinganexcessmarginof2-2.5mm.

Fig.23.Drawingsofbraces1–brace№1;2–brace№2;3–brace№3

Atoolcalled"zakubrovka"(clampingbar)isusedtoattachthetoptothebody.Forthisoperationprepareaclampingcaul10x20x500mm,madeofpineorspruceanda20x40mmbirchplywoodpad.Youcanpre-drivetwotacksintothepad(SeeFig.24).Alsoprepare~10metercoilofropeorcordage(suchastwilltape).


26

Thebalalaikabody(6)ismountedonaworkbench(Fig.24)withaclamp(2).Inordertoensurethattheneck(3)doesnotsliponthebench(4),putalargepieceofsandpaperunderit,foldedinhalf,roughsideout.

Glueisappliedtothelining,neckblock,bracepocketsandbase.Thetopissetintoplace.Duringthisprocess,exercisetheutmostcautionregardingthesoundboardcorners.Withthehelpofapadpresstheupperpartofthetoptotheneckblock.Placetheclampingcaul(5)onthetop,andpressitdowntothebasewithyourlefthand.Putyourrighthandonthenaildrivenintotheneckblock,andloopa0.5mmstringaroundit,passingitunderthebody,andaroundthetoptothesecondnail.

Havingroundedthesecondnail,theropeprotrudesfromunderthebottomofthebodyattheleftcornerandwithtwowrapssecuresthecornerofbody,thesoundboardcornerandtheleftendoftheclampingcaul.Thenwiththeropepassedunderthebody,therightcorneroftheinstrumentissecured.Thencontinuetowraptheropeforseveralmoreturns,asshowninFig.24.Therighthandcontinuallystretchestheropeandtheleft,holdingthesoundboardinthecorrectplace,holdsthebodyoftheinstrument.Sometimesitisnecessarytoholdthebodywiththeknee.Sothattheropedoesnotslipontheclampingcaul,itispossibletomakesmallnicksinthezakubrovkawitharoundfile.Theglued-upsoundboard,asifswaddledwiththerope,shouldbecheckedalongtheedgeoftheglueline.Ifyounoticeanygaps,closethem,pullingtheropetighterwithwedgesinsertedunderitfromthesidesofthebody.

Theprocessofattachingatoprequiresgreatskill,beforetheadhesivehastimetoset.Therefore,forthedevelopmentoftheseskillsthisprocessshouldberepeatedseveraltimesonaplywoodtop,ofcourse,withoutglue.


27

Fig.24.Gluingthetoptothebodyofthebalalaika:1–plywoodscrapwithtwotacks;2–clamp;3–neck;4–bench;5–clampingbar;6–balalaikabody;7–string

After4-5hours,i.e.,afterthetopisbondedandguaranteedtobedry,begintrimmingalongtheoutlineofthetop.Dothiswithachiselorplane,andthencleanuptheedgeswithametalfileorrasp.Theedgeofthetopshouldhaveaverysmoothshape,withoutnicksorburrs.

Onthemarkingguage(orpurflingcutter)setthecuttertoawidthof5.5-6mm,witha2.5mmcuttingdepthandcutthecornersofthetoptoadepthof1mm,asshowninFig.25,a.Asoutlinedinthiswaythecornersaredecorativelyinlaid,theseareknownsimplyas"corners".Theymayhavedifferentpatternsorconfigurations.ThreeoptionsareshowninFig.25,б.Theyareinlaidintothecorners,liketherosette.Thedesignofthecornersischosenbasedontherosette.


28

Fig.25.Inlaidcorners:a–cuttingofthetopsurfacewithatrim(purfling)cutter,andб–cornerdesignoptions


29

Fig.26.Gluingbindings:a–bindingcrosssection;1–stripofdarkveneer;2–stripoflightveneer;3–‘rail’ofdarkbinding;б–layingrope:1–clamp;2–neck;3–bindings;4–rope

Thetop,withthecornersdried,isthenpreparedforattachingthebindings.Todothis,thewidthofthecuttingsurfacegauge(purflingcutter)isincreasedby0.5mm.Cutthroughthesoundboardwiththepurflingcutteralongtheedgetothelining,thatis,theentiredepthofthetool.Neartheneckblock,wherethesurfacegauge(purflingcutter)doesnotwork,cutthroughwithaknifeorcutter(chisel).Astripalongtheedgeofthetopisneatlycutwithachisel,enablingaplaceforalayerofglue.Aheavilyknurledquadrangularmetalfileisusedtocleantheresultingslotforthebinding.

Glue1-2stripsofdyedveneertothebinding(Fig.26a).Thelengthofthebindingandveneerisdeterminedbythemeasurementsoftheedgeofthetopplusanextra20-30mm.Thebinding,gluedfromthebasesideshouldhaveabreakof10-20mmalongtheaxisoftheinstrument.

Firstrefinethefitofthebindingsinthecornersofthetop.Mediumviscosityhideglueisthenappliedtothetwogluingsurfacesofallofthebindingsandputintheirplacesinthecornersofthetop(seeFigure26.б.).Tiealoopofropeontheleftcorner,withthebindingsinplaceandpullonit.Thentheropeistransferredacrossthetoptotherightcornerwhereyoumake1-2turns,tightlyclutchingthebindingstothebodyandthetop.Further,theropecrossesthebaseandleadsouttothetopandaloopofabout20-25mmisplacedontheleftcorner.Make4turnswiththerope,asshowninFig.26,б.Withthefinalturns,tietheendsofthebindingsintotherabbetsattheneckblock.

Oncethebindingshavedriedoutalittle,theyarescrapedflushwiththeendwedgesandbasewithafilefromthebodyside.Fromthesoundboardsidethebindingisplanedwithablockplaneflushwiththetop.

Finishingthesoundboardbeginswithfillingallvisibledefectsonthesurfaceandallgluedjoints.Afterthefillerisdry,scrapethetoptolevel.Thescrapingdirectionisfromthecornersalongtheaxisofthetop,atanangleof45°,andtheninadirectionparalleltothetop.Onaproperlyscrapedtopyoushouldnotfeelanybumpswiththefingers.

Polishthetopwithwet-drysandpaper,usingafeltpadbacking,inthesamedirectionandthesamesequenceasthelevelingprocess.Thesoundboardisthenrubbedwithalcoholtoraisethegrainandthenpolishedagain(raisingthegrainwithwaterisnotrecommended).

Preparea“tampon”(muñeca)madefromcottonjersey,anduseittoapplytwocoatsofnitrolacquersealertothesoundboard.Theoperationisrepeatedtwomoretimesatintervalsof15-20minutes.

Thecarefullydried,primedsurfaceisfinesandeduntilasmoothmattefinishisachieved.Sheetsofsandpaper60X80mm,arefoldedinhalfandheldwiththethumb,indexandmiddlefingers,with


30

slightpressureonthepaperassistedbytheothertwofingers.Sandingthenitrolacquershouldgeneratelightdust,whichsuggeststhatitiswelldriedout.

Spiritvarnishisusedforthenextcoatingofthetop,doneinthesamesequenceasthenitrocelluloselacquerfinish.Anystainsareextremelyunacceptableintheappearanceofthetop,anddropsoflacquerevenmoreso.10-12layersofshellacvarnishareappliedanddried1.5-2hoursinawarmwell-ventilatedroom.

Thedriedsurfaceofthetopissandedusingfinesandpaperfollowingthesamemethodasthenitrolacquerprimer.Inthisprocessuseincreasedaccuracyandattentiontoavoidsandingthroughthevarnishsurface.Thisleadstotheappearanceofwhitishspotsonthetop,whichcanonlybecorrectedbyremovingallthefinishandstartingagain.Awell-polishedshellacvarnishlayergivesadeepmattefinishwithveryrareandsubtleglimpsesofthegrain.

Thepreparedsurfaceispolishedusingpumicepowder.

A‘tampon’(muñeca)ofcottonislightlymoistenedwithlubricatingoil,letitsoakinanddipthe‘tampon’(muñeca)intothepumicepowderthathasbeenpouredout.Afterrubbing,wipedrywithasoftcloth.Thetopshouldhaveadullmattefinishwithoutanyshine.

Afterpreparationproceedontopolishthetop.Onaprepared‘tampon’(muñeca)ofwhitelinenintroducetheshellacpolishandputitintoasealedcontainer.Forbetterimpregnationthecontainerisputinawarmplace.After15-20minutesthe‘tampon’(muñeca)isslightlypressedagainstthebackofthehand,leavingathin,fastdryinglayerofpolish.Polishthetopwiththe‘tampon’(muñeca)untilmovementofthe‘tampon’(muñeca)becomesdifficult.Finishthepolishbybrushingthe‘tampon’(muñeca)with2-3dropsoflubricatingoilforeasymovement.Anhourlater,theinstrumentisreadyforthenextcoat.

PreparingtheHeadstock

Thefailureofthegluejointbetweentheheadstockandtheneckisararephenomenon.Thereshouldbemuchattentionpaid,whichthebuildermustgivetothisarea,andobviously,agooddesignofthejointitself.

Theheadstockisconnectedtotheneckofthebalalaikawithhideglue.Forthis,wefirstdeterminethepositionoftheheadstockontheneck.Theheadstock(Figure27)issetontheneck,focusingonthelocationoftheinstallationlines(4)(seeFig.4).Forcontroltheapproximatesizeisindicated-86mm,whichcorrespondstotheintervalbetweenwherethe3rdand4thfretswillbelocated,i.e.itistheendingpositionoftheheadstockintheplaneoftheneck.Sawalongtheline(6)(seeFig.27)withabowsawleavingamarginof1-2mm.Thisjointisworkedwithasmoothingplanewithachipbreakerjustalongtheline(6),andthentuneupthesurfaceafewtimeswithascraperplane.Checkthefitof


31

theplanedsurfacebyplacingtheheadstockportionagainsttheareawhereitwillbeglued.Thewedgethatwassawnofffromtheneck(5)shouldbesaved.

Beforegluing,pre-heattheheadstockbyplacingitonahotstove.Glueisappliedfirsttotheneckintheglue-uparea,andthenontheheatedheadstock.Usingaclamp(3)ensuresthegluedpartsarewellbonded(Fig.28).Sothatthewedge(4),placedundertheclamp,doesnotslipofftheplaneoftheheadstock(2),itismoistened.Observecarefulalignmentofthepartswhengluing.

Fig.27.Diagramfordeterminingthepositionoftheheadontheneck:1–thebodyoftheprimabalalaika;2–neck;3–headstock;4–Adjustingtheline;5–sawoffawedgefromtheneck;6–sawline;7–balalaika-primanecktemplate

Afterthejointisdry,useabowsawtocutawaythepartoftheheadstockprotrudingabovethetopplaneoftheneck.Thenthesurfaceoftheneckiscarefullyplanedwithasmoothingplane(aplanewithachipbreaker)andthefitistested"bycandling".Here,thesoundboardsurfaceliesinthesameplanewithoutrefraction,asdoesthefingerboardthatisgluedtotheneckandwhoselowerpartisgluedtothesoundboard.

Theconnectionofthebalalaikabodystaveswiththeneckheelmayhavegaps.Forthisgapsawaslottoadepthof2.5-3mmandglueinastripofdyedveneer.Afterthegluehasdried,scrapeofftheexcesswithaknife,andcleanuptheveneerstripwitharoundrasp.

Thefingerboardismadefromabillet(6-7mminthickness)ofebony,stainedbeechorpearorotherspeciesresistanttowear.Afingerboardtemplateforthebalalaika-primaisshowninFig.29.

Thetemplateisplacedontheneck,aligningthelateraledgeofthetriangularsectionwithalineconnectingtheneckwiththebody,andthendrawtheoutlineofthecontourofthelowerpartofthetemplateonthesoundboard.Completelyremoveanylayersoflacquerwithaknifeorscraperfromwithintheoutlinedareaofthesoundboard.


32

Roughenupthebottomsurfaceofthefingerboardandtheupperplaneoftheneckwithatoothedplane.Withanawlcreatetwoholesintheneck50mmfromthebeginningandtheendalongtheaxisofsymmetry.Placecutofftacksintotheholessothattheirsharpendsprotrudeabovetheplaneoftheneck1to1.5mm.Duringtheprocessofgluingthese"teeth"willkeepthefingerboardfromsliding.

Fig.28.Attachingtheheadstocktotheneck1–neck;2–headstock;3–clamp;4–wedge

Havingsetthefingerboardtoheatuponahotplate,theadhesiveisfirstappliedtotheneckneckandsoundboardarea,andthenontheheatedfingerboard,connectthemtogether,maintainingalignment.Clampingthegluedjointisdonewith2-3clamps(Fig.30).Pressurefromthetightenedclamps(1)istransmittedtothefingerboard(3)throughtheclampingcaul(2).Excessadhesiveprotrudesfromunderthefingerboardaroundtheentireperimiter.Ifthereisariskofapoorgluejointbetweenthefingerboardandthesoundboard,thenbetweentheclampingcaul(2)andthefingerboard(3)youcaneasilyinsertasmallwedge(6)toapplymorepressure.Oftenthebuilderplacesapieceofwalnutorbirchveneerbetweenthefingerboardandtheneck.Afterthegluehasdriedtheexcessisremovedwithaknifeorchisel.

Thescaletemplateisplacedontheglued-upfingerboard(2)(Fig.31).Theaxisofthetemplatemustbeaccuratelydirectedalongtheaxisoftheinstrument,andthe16thfretshouldstandabovetheveneerstripseparatingtheneck(4)fromthebody(5).Inthisposition,thetemplateispressedagainsttheneckwithaclamp(1).

Fretslotsarelaidoutandcutwithafinetooth1mmsawtoadepthof1-1.5mm.Thetemplateisremovedandthecutsaremadetotherequireddepthwithafrettingsaw.Forbettercontrolofcut,depth-limitersintheformoftwoplatesareattachedtothesawbladeonbothsides.Thedepthandwidthofcutdependsonthefretwireused.Ifthecuttingdepthiseasilyadjustablewithlimiters,thewidthcanbeincreasedbyslightlyswingingthebladefromsidetosideduringtheprocessofcutting.


33

ThetechnicalsequenceofprocessingtheneckisshowninFig.32.Tofacilitatereadingthediagram,thebodyandtheheadstockoftheinstrumentarenotshown.Beginbymakingthreecutsintheheelwithabowsaw(Fig.32,а,б).Furthertreatmentoftheneckisdonewithachisel,withallprecautionsandalwayswithemphasisonusingarubbermatonthebench.Itismostdesirabletobegintheprocessofcarvingtheprofilewithachisel(2)(Figure32,в).Thisplaneisthebasisforfurtherprocessingandexceedstherequiredfinalsizeoftheneckby1-1.5mminheight.Thenshavethesides,leavingtheremaining1-2mmtobeworkedwiththerasp.Theprofileandcontoursofthenecksectionsareshowninthefigureatline(3).Whenprocessingtheneckblanksyoumightencountercurlygrainandthechiselwillproceed"withdefiance".Changethedirectionofcuttingtoavoiddangeroustearoutofthewood.

Fig.29.Balalaika-primafingerboarddrawingtemplate

Fig.30.Attachingfingerboardtotheneck:1–clamps;2–clampingcaul;3–fingerboard;4–neck;5–body;6–wedge


34

Fig.31.Fretslotpreparation:1–clamp;2–scaletemplate;3–fingerboard;4–neck;5–body

neckblanksFig.32.Preparingneckblanks:a,б–preliminaryheelcarving;в–processedheelandneck;1–originalprofile;2–profileaftertreatmentwithachisel;3–thefinalneckprofileandcross-sections


35

Fig.33.Modelforcarvingtheneckheelandjoiningtheneckwiththeheadstock:a–neckheel;b–joiningtheneckwiththeheadstock

Themostdifficultareasarethetransitionzonesintheneckandheel,andtheneckandheadstock.Itisverydifficulttoidentifyanycontrolpointsorapplyanytemplates.Intheseplaces,necktreatmentisentirelydependentontheexperienceandtasteofthebuilder.TherecommendedheelmodelandheadstocknecktransitionsareshowninFig.33,а,б.

Finishworkingtheneckneckwithafile(rasp)withvariousprofilesandknurlpatterns.Thenecksurfaceisthenscrapedandcleanedupwithvariousgritsofsandpaper.

Fig.34.FretShapinga–shapingtheendsoffretwire:1–fretwire;2–fingerboard;3–neck;б-formationofthefretprofile:1,2–planeobtainedfromshapingwithafile;3–planeobtainedbyspinningfrets;4–finalfretprofile;5–fretwire;6–fingerboard;в–modelfortreatingtheendsofthefretwire


36

Fretmarkersonthefingerboardareinstalledafterthe1st,4th,6th,9th,11th,14th,16thand18thfrets,withthefinaltwomadeasmallersize.[Trans:Thisisanotherwayofstatingthatthefretmarkersareinstalledatthe2nd,5th,7th,10th,12th,15th,17thand19thfrets.]

Holdastraightenedpieceoffretwireinthelefthand.Lubricatethetangofthefretwirewithliquidadhesiveandhammeritintotheslots.Ifthetangisdifficulttoinsert,theslotcanbeeasilyexpandedbysawingslightly.Whentheslotistooloose,resorttousingafillerwhichcanbemadefromsawdustandliquidadhesive.Excesswirecanbenippedoffwithcutters.Particularcautionshouldbeexercisedwhendrivingfretsintothelowerpartofthefingerboard,whichisalreadygluedtothesoundboard.Toavoiddamagingthesoundboardblowswithahammermustbelightandeasy.

Theprocessofworkingthefretsiscalledseamingorflanging(закаткаinRussian-zakatka).Begintheflangingprocessbystrippingtheendsofthefretwireprotrudingfromthesidesoftheneck.Dothiswithaheavilyknurledmetalfile.Themotionofthefileshouldbesuchthattheendsofthefretshavenoburrs,andtheendsthemselvesbecomerounded(Fig.34a).Thenallofthefretsareleveledwithafiletothesameheight.Forthis,afileisplacedonthefretsand,pressingdownlightlywiththehand,andismovedalongthefretboard.Thisprocesscontinuesuntilalltracesofthefileovertheirentirelengtharenolongernoticeableandthefretsarelevel.Usuallythisprocessiscalledlevelingthefrets.Inthismanner,theflattenedarea(orplateau)(3)isshownonthefretwireprofile(Fig.34.б).Angles(1)and(2)areobtainedbyshapingthesidesofeachfretwithafile.Roundoutthetrapezoidalprofile(4)ofthefretswithaspecial(fret)file.Theendsofthefretwire,facingthesidesoftheneckaresmoothedwithneedlefiles,seekingtheformshowninthemodelinFig.34,в.Finishworkingthefretswithabrasivesandpapers,lappingeachfretseparatelyandthenalltogether.[Trans:Besuretomaskthefingerboardduringthisprocesstoavoidanyunnecessaryscratchesordings.]

Whenviewedfromthebasealongthesurfaceofthefingerboard,thefretshavetobemergedintoasinglebandwithnolightanddarkspots.Thefretsshouldnothaveanysharpnicksorbumpstothetouch.


37

FabricationandInstallationoftheNutsandthePickguard

Thefirstcutintothefingerboard(Fig.35a)ismadetothedepthofthefingerboard.Theresultingsocketiscleanedwithachiselandapieceofebonyorotherhardwoodmeasuring6x8x35mmisgluedintoit.Afterdrying,theuppernutisworkedwithachiseltotheprofileshowninFig.35б.

Fig.35.Layoutfortheuppernuta–preparingtheslotfortheuppernut:1–fretboard;2–cutlayoutundernut;б–diagramofuppernutshowingprincipaldimensions

Fig.36.Layoutforthelowernut1–soundboard;2–binding;3–pinblockcover;4–basewedges;5–base

Thelowernutshouldalsobemadeoutofhardwoodsuchasebony,orbone.Arabbetunderthenutisprepared,asshowninFig.36.

Thepickguardforabalalaikaismadeofpolishedbilletsofdyedbeechorpear,3-4mminthickness.Forourpurposes,wemayusethree-layerbirchplywoodwithoutknotsifbeechorpearisnotavailable.Thefirstpartofthepickguardcontour(AGF)(Fig.37)iscutwithajigsaworathinbowsaw.Chamferingisdonewithraspsandfiles.Thepolygonallineshowninthefigure,asABCDEF,showsthesecondpart


38

ofthepickguardoutline.Placethebilletpieceontopofthebalalaikabody,andtracetheoutlineofthebodyandthefretboardendwithapencil.CutoutthepickguardbilletBCDEunderthefingerboardmakingit2mmnarrowerand4mmshorter(providingsomeallowance).

Fig.37.Thumbnailofthepickguardbillet(viewedfromlowerside)1–drawingofcuttingthepickguardbillet;2–pickguardcross-section;3–cross-sectionofgluedveneergaket

1.5-2mmveneergasketsorstrips(3)aregluedontothebottomofthepickguard.[Trans:Thesegasketsholdthepickguardabovethesurfaceofthesoundboardtoallowthesoundboardtofreelyvibrate.]Thebevelangleis15°,whichismadealongareasBCandDE,ensuringatightfitofthe


39

pickguardandthefingerboard.ThesiteCDisconnectedtothefingerboardwiththehelpofashoulderpad(Figure38).Thepickguardisjoinedtothebodywithglueonthegasket(6)andseveralwoodennails(10).Notchesunderthenailswerepreviouslyprickedwithanawlorboredwitha1-1.5mmdiameterdrill.ApproximatenailinstallationlocationsareindicatedinFig.37bystars.Removeanylacquerfromthesoundboardattheareaofattachmentbeforeinstallingthepickguard.Payparticularattentionthatthesurfaceofthepickguardislevelwiththebottomofthefingerboard.Fillanyslitsorgapsbetweenthem.

Fig.38.Diagramforstrengtheningthepickguard:a–placementofthecross-section,бandв–thetransverseandlongitudinalcross-sections:1–pickguard;2–fretwire;3–fingerboard;4–heel;5–soundboard;б–gasketunderthepickguard;7–binding;8–lining;9–bodystaves;10–woodennails

Fig.39.Sketchesofthebridgebilletandfinishedbridgeа–bridgepreparation;б–bridge


40

Fig.40.Diagramfordeterminingtheheightofthebridge:h–theheightofthebridge;A–thedistancefromthetopofthenuttothe12thfret

Thebridge(usuallycalledapodstavka,butsometimescalledakobylka)canbemadefromamapleorbeechbillet,lessfrequentlyfrombirch(Fig.39,a).Ashimorstripofebony,rosewoodorotherveryhardwoodisgluedtothetopofthebridge.ThefinalsizeofthebridgeisshowninFig.39,б.ThebridgeheightatthecenterisdeterminedbythediagramshowninFig.40.


41

FinishingtheInstrument

Finishingtheinstrumentstartswithadampshopcleaning,asdustisthebitterenemyofthewoodfinishingprocess.Youneedtochangeyourapronorgownandwarmtheroomto24-27°C.Thenmakeacarefulexaminationoftheoutsideoftheinstrument.Anygapsorcracksfoundshouldbefilledwithamixofsawdustandliquidhideglue.Fillersmustbecarefullyapplied,tryingnottostainthesoundboard.Ifthisshouldhappen,dampenaclothtoremoveanyuncuredfillerfromthepolishedsoundboard.

Thedriedbodyisscraped.Thebodyoftheinstrumentissupportedinthiscaseinthelaporbetweentheknees,andtheheadandneckarepressedagainstarubberstripontheedgeofthebench.Scrapealongeachstaveseparately.Onaproperlyscrapedbodythesurfaceofthestavesaccuratelyshowstheseparateveneerstrips(veins)inbetween.

Thebaseisscrapedfarandwideacrosstheentiresurface,whileavoidingbeingoverlyaggressive.Otherwise,changethedirectionofscraping.

Scrapetheneck,beginningwiththeheel.Inthis,thescraperisworkedsmoothlythroughthestrip(vein)separatingthebodyfromtheheel.Whenscrapingtheneck,monitorsoasnottohaveformedanyridges.Theseshouldberemoved,workingthescraperinaspiralorcirculardirection(Fig.41).Theheadstockisscrapedinthedirectionfromtheheadtowardthebody,alsoavoidinganyridgesoredgesonthefacesoftheovalsurfaces.

Thebodyandneckaresandedwithfinesandpaperinthesamemanneranddirectionasthescraping.Itisrecommendedaftersandingthattheworksurfacebewipedwithalcoholtoraisethegrain.

Beforeapplyingthelacquertothebody,thelacqueredsurfacesoftheheadandneckheelareprimedwithnitrocelluloselacquerNC-222orsimilar.Primingthebodyandtheneckisdonewiththesametechniqueasprimingthetop.Thepartoftheneckareawherethemusicianslidesthepalmofhishandduringplayingshouldnotbetreatedwithlacquer(Fig.42).

Lacquerthebodyandtheneckwithshellacvarnishusinga‘tampon’(muñeca)inthesamesequenceaswasdonewiththesoundboard.Thesameprocessorsequenceisfollowedwhensandingandpumicepolishingthelacquer,aswellasthesubsequentpolishingofthebody.


42

Fig.41.Diagramforscrapingandworkingtheheelandneck1–directionofscrapingtheheel;2–directionofscrapingtheneck

Fig.42.Thepartoftheneck,whichisnotvarnished.

Carefulattentionshouldbepaidwhensandingthelacqueredsurfaceofthebody,asitispossibletosandthroughtothewood.

Whenpumicingthebodyandneck,alsotreattheneck.Thesameoilypumicepowdergetsintotheporesoftheunvarnishedneckandsoaksintoit.Thistreatmenttotheneckisconsideredsufficient.

Quiteoften,thebuilderisnotsatisfiedwiththenaturalcolorofthebodywood.Inthiscase,youcanmakeabodywashafterthebodyispolished.Thedyemustbedilutedinthecorrectproportionsandalwaystestedonaboardofthesamespeciesasthebodystaves.Toobtaingoodresultsthe‘tampon’(muñeca)withdyeisapplieduniformlyalongthestavesofthebody,withoutrunsandinevenpasses.Thedyed/paintedsurfaceshouldnotbetoowet.Afterdrying,rubthedyed/paintedsurfacewithapieceoffelttogiveaslightsheen.Thenproceedtotheprimerandsubsequentnitrolacquerfinishingoftheinstrument.Rememberthatwhensandingthroughthecoloredbody,unpaintedwoodmayemerge.Suchadefectcanonlybecompletelyeliminatedbythoroughlyscrapingandrepeatingallofthesubsequentoperations.


43

AssemblingtheFinishedBalalaika

Assemblyofthefinishedbalalaikabeginswiththetuningmachines.Insertthemechanismintotheslotpreparedforit.Placetworubbergasketsbetweenthegearsofthetuningmechanismprotrudingabovetheheadstockby0.3-0.5mm.Thetuningmachinecoverwillcompressthegasketsbythisamountandthusholdthetuningmachinesinplace.Thetuningmachinecoverisfixedtotheheadstockwith6-7screws,inholesintheheadstockmadewithanawlorsmalldrillbit.

Intheholedrilledintothebase,insertabutton(stringpin)(Figure43).Thebuttons(stringpins)mustbeinsertedintotheholestightlybyhand.Forthelast2-3mmitisallowedtotapwithlighthammerblows.

Fig.43.Drawingofthestringpin.

FordeterminingthelocationofthebridgeyoucanusethediagramshowninFig.40.Afterdeterminingtheplacementofthebridgeatadistanceof2Afromtheuppernut,placeadotthere,lightlypushingthepencilleadintothepolishedsurfaceofthesoundboard.

Makeslotsforthestringsontheupperedgeofthebridgeandtheuppernut(Fig.44).Thedepthoftheseslotsshouldnotexceedhalfthediameterofthestringbeinginstalled.Excessivedeepeningoftheslotsmaycausebuzzingofthestrings.

Installthreestringsonthebalalaika-prima.String(3)ismetal0.25mm(.010,but.011and0115arecommonsizes),andtwosyntheticstrings,usuallynylon,1mm(.039,butClassicalGuitarGstringsaround.04arecommonlyused).Thestringsshouldnotstretchmuch.Whentransporting,itisrecommendedtoputthebridgeonitsside.


44

Fig.44.Layoutofthestringsonthenutandbridge-primabalalaika1–bridge;2–syntheticstrings;3–metalstring;4–uppernut


45

TheTechnologicalProcessofFactoryProductionofBalalaikas

Serialproductionofthebalalaikaisbasedonthesamebasictechnicalmethodsandoperationsasthatusedinthemanualproductionprocess.Industrialproductiondiffersonlyinthemoregeneraluseofwoodworkingmachines,usingstandardtoolsandtemplates.Thebalalaikabodyisgatheredupfromsixstaves,fixingthemontheneckandthebase.Thebodyassemblyisperformedonaspecialdevice.Thisdeviceissoconstructedastohavefundamentaldifferencesfromthepatternsofimprovisedstructuresusedinhandmadebalalaikaconstruction.Techniquesforworkingonsuchastructurealsodonothaveanynewelementscomparedtothosealreadyconsidered.

Bracesaregluedtothesoundboardinpneumaticpresseswithresistanceheating.Alongwithgluingthebracestothesoundboard,thearchingiscreated.Thesoundboardisgluedtothebodyofthebalalaikainpneumaticpresses.Thepocketsforthebracesunderthesoundboardarecutoutonamillingmachine.Thesoundboardisgluedonwithhideglueandkeptinspecialfixturesfor4-6hours.

ThebalalaikafretboardisgluedonwithadhesiveM-70orK-17inpneumaticpresseswithlow-voltageelectricalcontactheating.Theheatingtemperatureis120-140°C.Itiskeptinapressurizedstate4-5minutes,thenclamped2-4hoursafterward.

Theslotintheendoftheneckundertheheadiscutwithamillingmachine.Theheadstockisgluedwithhideglue.Theheadstockangletotheplaneofthefingerboardis12°.

Afterplaningthefingerboardonthemillingmachine,fretslotsaresawnintothefingerboard.Thisoperationisperformedonascalecuttingmachine,whichhasseveralcircularsawbladesonasingleshaft,thenumberofwhichcorrespondstothenumberoffretslotsrequired.Thesawbladeshaveathicknessof0.7-0.8mm.Theworkingpartofthesawbladesissettotheheightofthefretwiretang.

Sandingofthepreparedbalalaikasisdoneintwoways,onverticaldisksandingmachinesandwithsandingrollers.Areasthatthemechanicalsandingcannotreacharethenscrapedandsandedbyhand.

Thepreparedbalalaikabaseandbodyarestainedandtheneckblackened.Afterthestainisdry,nitrocelluloselacquerisappliedusingconventionalspraying.Inrecentyears,ithasbecomeawidespreadmethodtoapplyvarnishelectrostatically.

Inordertosavewoodandincreaseproductivityatthe“LeningradLunacharskyFactoryofFolkMusicalInstruments”,theydevelopedandputintoproductionamethodformakingbalalaikabodiesfromwood-pulp.Fromchipsandwastepaper,withtheadditionofphenol-formaldehyderesinandaspecialsizingagenttheycastbalalaikabodies.Afterpressinginthemoldat150-160°Candasurfacepressureof8MPa(80kg/cm2)yougetareadybalalaikabody,whichgoestoassemblyusingconventionalwoodenbalalaikamanufacturingtechniques.Enhancedaestheticandacousticrequirementsforsuchinstrumentsarenotconsidered.


46

BalalaikaRepair

Balalaikascominginforrepair,asotherstringedmusicalinstruments,mayhavepronounceddefectsthatneedtobeaddressed.Repairsaredoneintwoways:withoutopeningtheinstrument,i.e.withoutseparationofthesoundboardfromthebody,andopeningthebody.

Iftherepaircannotbemadefromtheoutside,thebalalaikaisopenedinthefollowingsequence.Removethestrings,tuningmachines,andbuttonsandthenplacethemneatlyaside.Usingathin,broadknifewitharoundedblade,occasionallydippingitinhotwater,separatethepickguardfromthebodyandfingerboard.Havingremovedthepickguard,ifyouwanttopreserveit,cleantheglueandresiduefromthemountingnailsandsetaside.Alsocleantheadhesiveresiduefromthepickguardoffthetop.

Iftherepaironcestarteddoesnotrequirechangingthefingerboardandtogetherwithityouwishtopreservethesoundboard,takeoutthe16thfret,i.e.thatfret,underwhichthebodyisjoinedtotheneck.Fretkerfscanbedeepenedalongtheentirethicknessofthefingerboard.

Usingaroundedblade,warmingitinhotwater,carefullyseparatethetopandsoundboardfromthebody.Particularcareshouldbeusedintheareaofthesoundboardcorners.Withthesameknifecarefullyseparatethesoundboardfromthelininganddevelopthisgapalongthelining.Thepointswherethebracesextendintotheliningsshouldbeavoided.Havingseparatedthesoundboardfromthelining,begintoseparateitfromthebase.Thisisalsodonewiththeroundedknife.Withanarrowchiselorcutterremovethebracesfromtheirpocketsinthelinings.Itisveryexactinganddifficultwork,andhasteshouldnotbetolerated.Thelastsectionofthetoptoberemovediswhereitisgluedtotheheeloftheneck.Thelowerpartofthefingerboardwithfretsremainsonthesoundboard.

Ifthefingerboardisofnovalueandyouplantochangeit,theninordertoopenthebalalaikaremoveallofthefretsandthenutandplanethefingerboarddown.Thesoundboardisremovedbytheabovemethod.

Significantlylesscommonisopeningthebackofthebalalaikabody.Todothis,cutoutandcarefullyremoveoneofthestaves.Aftermakinganyrepairs,suchasreplacingorrestoringbraces,thestaveisgluedbackinplacewiththehelpofpatches.


47

CrackRepair

Fig.45.Diagramforfixingacrackwithaninsert:1–insert;2–edgeofthecrack,cut"intotheface"

Crackscanappearinanypartoftheinstrument.Ifthecrackissmall,thenpourhothideglueintoitandcarefullywrapwithrope.Forgreaterconfidenceintightlypressedparts,woodenwedgesareslippedundertheropeduringgluing.Wedgescanalsobeusedtocontrolthecrackheight.Aftergluingthecrackarea,sandandvarnish.

Thecrackmayhavearatherlargewidth–0.5-1mm.Inthiscase,useaninsertasshowninFig.45.Theedgesofthecrack(2)arecut"intotheface",andtheedgesoftheinsert(1)arealsocut"intotheface".Aclampisthenwoundwithrope.

Whenrepairingcracksandcrevicesintheornamentsandthefaceofthebindings,useanadhesivefillerofsiftedsawdustofthedesiredcolor.Sometimespartorallofthetrimisreplacedorchanged.Followthesameprocedureasisdoneduringtheassemblyofanewbalalaika.

Cornersofthesoundboardthathavefallenoutorsoundholerosettesorpinblockcoversarerepairedbyreplacingthelostitemswithnewones.Carelesslytreatedcornersofbalalaikascanbedyed.Anycracksandcrevicesthathaveappearedcanbefilledwithadhesivefiller,dyedtotheappropriatecolor.Forlargeareasofcornerdamage,thedamagecanbecutoutandalldamagedelementsthatconvergeatthecornercanberestored.

BodyRepair

Theremaybeholesinthestavesofthebalalaikabody.Thepreferredrepairistoreplacethestave.Abrokenstavecanbeneatlysawnandcutoutwithsomekindofcutter.Anewstaveisprepared,chosenbywoodtypeandgrain.Apatch(1)(Fig.46)ofsprucemeasuring20x20x3mmisgluedfromtheinsideonthesidesofthestave(2).Thenewstaveisshapedtoprovideasnugfittothepatch.Alongthelengthofthestavetakeintoaccounttheveneerstripgluedtoit.Afterfittingandgluingthestave,


48

touchupthecolorandthenvarnish.Qualitystaverepairsadjacenttothesoundboard/top,withoutremovingthelatter,areverydifficult.Withnewinsetstaves,itisrecommendedtobendthemalongthebodyusingthehotpipeorbendingiron.

Fig.46.Installationofpatcheswhenreplacingastaveinthebalalaikabody:1–patch;2–stavesofthebalalaikabody;3–pocketintheneckheel;,4–bassbinding;5–base;6–wedgeonthebalalaikabase

Thereisrarelyanyneedtochangeordoadditionalworkonthetopbraces.Evenmorerarely,thebuildermaydecidetoreplacethetop.Bothoftheseoperationsmustbecarriedoutbyopeningthebalalaikabody.

NeckRepair

Thedestructionofthebalalaika’sneckheelrarelyhappensandusuallymeansthedeathoftheinstrument,aswellascompromisingtheintegrityoftheconnectionbetweenthebodyandtheneck.Itissignificantlymorelikelytohavetocorrectaneckdefect,likeconcavityorwarping.Constantstringtensioncandeformtheneckandmakesplayingtheinstrumentdifficult.Repairbeginsbyremovingthepickguard,uppernutandfrets.Thefingerboardcaneitherbeplanedofforremovedwithasemicircularknife.Beforeremoving,placearagsoakedinhotwateronthefingerboardfor10minutes.Thisfacilitatesremovingthefingerboard.Planetheneckflatandputonanewfingerboard.Thethicknessofthefingerboardisdetermineddependingonthedesiredcrosssectionsizeorthicknessoftheneck.Furthertreatmentoftheneckisnotdifferentfromthatpreviouslydescribed.


49

Themostfrequentrepairisfretting.Underthefirststring,indentationswillform,impedingthemusician’splaying.Ifthereissufficientheightlefttothefrets,thentherepaircanbeconfinedtolevelingallfretswithawide,coarsefile.Thenshapethefretsbytheusualmethods.Ifthefretsarewornout,thentheyareremovedwithnippersandreplacedwithnewones.Itisbesttoremovethepickguardduringtheseoperations.

ThoughtsonRepair

Themaintaskofthebuilderduringrepairworkistopreserveand,ifpossible,improvethesoundoftheinstrument.Ofgreatimportanceinthisregardisthepreservationofthesizesoftherepairablepartsandtherelationshipsbetweenthesedimensions.Forexample,increasingthethicknessofthefingerboardorincorrectlylevelingraisesorlowersthelastfrets.Thisinturnresultsinanincreaseordecreaseintheheightofthebridge.Increasingtheheightofthebridgeincreasesthepressureonthetop,andanyreductionintheheightpreventsplayingtheinstrumentandmakesitdifficultfortheformationofthepickguard.Therefore,whenstartingarepairoftheinstrument,thebuilderrecordsandsketchesthemainelementsoftheinstrumentandtheirco-locations.

Amusicianmayaskthebuildertomakechangesinthedesignoftheinstrument,andthebuildermustknowwhatoptionshehasdependingonthesedesiredchanges.Ifnecessary,thebuildermustdefendhisopinion,asthequalityofrepair,aswellasthesoundqualityoftherepairedinstrument,isentirelydependentonhim.

Repair,donetomusicalinstrumentsisverylaboriousandtime-consumingwork.Manybelievethatitiseasiertobuildanewinstrumentthantorepairanoldone.Butinrepairwork,thefuturemasterreceivesinvaluableexperience.Heseesavarietyofdesignsolutionsandcanunderstandandlearnnewtechnicalmethodsthatwerenotpreviouslyknown.Notfornothing,butthemasterbuilderandthemasterrepairmenarebothequallyvalued.


50

QuestionsandProblems

1. Whatarethemaincomponentsofthebalalaika?Whatmaterialisrequiredtoconstructtheseparts?

2. Inwhatorderarebodystavesofthebalalaikainstalled?

3. Atwhatfretisthefingerboardattachedtothebodyofthebalalaika?

4. Whataretherequirementsforthematerialforbraces?

5. Make3-4optionsforbalalaikasoundboarddesign.

6. Howdoyoudeterminetheplacementofthebridgeonthesoundboardofthebalalaika?

7. Howdoyouopenthebodyofthebalalaikaforrepair?

8. Howdoyouchangefretsonthebalalaika?

9. Howdoyoufixneckdeformation?


51

Contents

TheConstructionAndRepairOfBalalaikas _____________________________________________ 1

TechnologicalSequenceofBasicOperations _______________________________________________3

BasicConstructionParametersandInstrumentStructure ___________________________________6

MakingtheNeckBillet ___________________________________________________________________9

ConstructingtheBodyParts_____________________________________________________________12

AssemblingtheBalalaikaontheTemplateanditsSubsequentProcessing____________________14

PreparationoftheSoundboardandGluingittotheBody ___________________________________22

PreparingtheHeadstock________________________________________________________________30

FabricationandInstallationoftheNutsandthePickguard__________________________________37

FinishingtheInstrument________________________________________________________________41

AssemblingtheFinishedBalalaika _______________________________________________________43

TheTechnologicalProcessofFactoryProductionofBalalaikas______________________________45

BalalaikaRepair________________________________________________________________________46CrackRepair____________________________________________________________________________________47BodyRepair____________________________________________________________________________________47NeckRepair____________________________________________________________________________________48ThoughtsonRepair______________________________________________________________________________49

QuestionsandProblems___________________________________________________________________50

the construction and repair of balalaikas - …...the construction and repair of balalaikas 4...

Documents