Construction
A few words before we get started on the construction phase of the banjo. If you are only going to build one banjo you probably are better off buying a precut fret board. This will save you a lot of frustration and time. My banjo's are based on a 26 3/16" scale fret board. If you use a different scale you will have to adjust the neck accordingly. You can purchase this fret board from Stewart-MacDonald. The like is listed on my sight.
You will still need to find a way to produce the stretcher band and tone ring. If you can't find some one in your area to bend them up for you I will be glad to do it. Contact me for a price and time schedule. The brass and steel for the two should cost about $18.00. I have no idea what the cost to bend them would be at a fabrication shop. I know it takes me about an hour to produce the two.
Well that's enough chit chat lets get started and build this thing. I usually start by cutting out the 18 semi pie shaped parts for the rim. Draw an 11" diameter circle on a piece of poster board and divide it into six equal sections. Then draw another circle using the same center point with a 7" diameter. I prefer not to have a radius on the inside of the pattern. It is easier to work with the angles if you have one flat side. Cut out one of the sections to use as your pattern for the wood parts. See diagram NO.1 Cut out the 18 rim sections . Next take six of the pieces and arrange them in a circle. Mark each in relationship to the next. Carefully sand the correct angle on each and trial fit together. I use a large hose clamp to hold the part together so I can check the fit. Hold them up to a light and look for any light in the space between the blocks. Sand accordingly. The better the fit the stronger the rim. Find a flat surface large enough for the rim to set on and line it with wax paper. Glue up the parts and tighten the clamp down. Weight the blocks down so you get a flat plane. I do each section separately. When you have all three rings of six sections each glued up you are ready for the next step. Do not glue the three rings together at this time.
Now you will need a pattern for the stretcher band and also to use for the hole lay out in the rim. The brass for the band is 1/2" wide and the head has an 8" diameter. Draw two circles, one with 4" radius and an other with a 4 1/2" radius using the same center point. This will be the size of the stretcher band. Divide the circles in half. This line will be where the neck bolts go through and the center of the tail piece. It will also be where the stretcher band will be joined together. I put a bolt on each side of this joint in the band close to the seam. By doing this you don't necessary have to braze the ban together. Lay out 9 bolt holes for each half keeping the holes slightly closer to the out side of the rim so the bolts don't hit the head when it is installed. See Diagram NO.2