《 Ukulele - CP5 - Parts　》

◆　Inlay on Peghead Veneer
 

Peghead will be overlayed with rosewood or ebony veneer where logo is inlayed.
 Now paste logo print on shell blanks.
Drill a small hole in the center shown in picture where cutting starts.
 

Start fresh cut at the point of small hole until inner circle is cut off, then edge of logo for final cut.
Note) Do wear dust-proof mask or respirator preventing shell dust from breathing.
  Remove the burrs on the edges of logo to be smooth, using a file.
  Scribe the location of tuning machine and the logo on veneer board. This must be done with precision.
 

For making accurate cavity, it would be much useful and successful to use Dremel router with StewMc's router base.
Make a test cut to ascertain if the depth is correct.
After routed out, test fit the inlay piece and make any corrections necessary to fit the pieces snugly. Use a chisel to get rid of any gaps between shell and cavity.
  Cut out inlay and cavity.
  PIC shows inlay being fitted well.
People may say there seems some gaps in between but these are within allowable limits.
  Next step is to apply the filler mix.
Mix epoxy and hardner and add rosewood dust until a thick mix is obtained.
 

PIC shows filler mix already filled into cavity and gaps between inlay and cavity.

(It seems to be used too much filler so leveling the surface may not be easy.)
 

After dried, sand the whole surface level. #120 to 1000 grit paper will be used and polish clean with compound wax.

◆　Bridge
 

Grooves on the bridges to receive the saddle is 2.5mm wide and 4mm deep.

PIC shows routed out bridge blanks, above is mahogany and rosewood bridge below.
  Scribe the string slots according to plan.
 

In making bridges, it would be easy and successful to set a pair of bridges together on the vise.

Start sawing string slots.
  Next step is to drill holes where the end of strings are contained.
Then expand the holes with using a chisel.
  Sand holes with #180 grit paper. Enlarge the slot of third string to 1mm because third string has a diameter of 0.8mm that is rather thicker than other strings.

◆　Nut and Saddle
 

Ivory can be used for nut and saddle.

PIC shows nut on top, saddle below. Both wiil be shaped with beltsander and files.
 

Final shaping such as height of saddle and string slots on nut will be adjusted when putting strings.