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Post by johnjsgems on Mar 2, 2009 21:41:38 GMT -5
I had a guy call me with a strange problem. He makes banjos and inlays abalone shell in the frets. He is paying a lot for thin flat shell sections and wants to make his own. I suggested a flat lap but he doesn't want to mic them to keep them flat. I told him if he was using rock he could make thin slices but abalone shell wouldn't work for slabbing. I also thought maybe a facet machine but that would be cost prohibitive. Any ideas out there?
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Post by NatureNut on Mar 2, 2009 21:57:44 GMT -5
I think Jamie (Desertdweller) has done some shells, she might know. I wonder if it could be done with a Dremel...
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Post by parfive on Mar 2, 2009 22:59:34 GMT -5
John - That's not making sense to me: " . . . he doesn't want to mic them to keep them flat."
A micrometer's got nothing to do with flatness.
Seems like he's gonna have to lap/sand pieces of shell flat whether he likes it or not. He could even flatten pieces with a belt sander. Then polish with finer grits, as usual. If he's got the skills to make banjos and inlay, shouldn't be that big a deal.
Rich
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agatemaggot
Cave Dweller
Member since August 2006
Posts: 2,195
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Post by agatemaggot on Mar 3, 2009 0:15:48 GMT -5
He sounds rather confused, what's he smokin ?
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Post by mohs on Mar 3, 2009 1:38:07 GMT -5
he better stick to pick'n grin'n
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Post by johnjsgems on Mar 3, 2009 1:46:40 GMT -5
I suggested he lap both sides but he wanted it exactly 1/16' thick with no variation which is why he mentioned using a micrometer to check for accuracy. He figures the Chinese can do it so he should be able to. I would have mentioned the labor rate difference but was trying to be nice.
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Post by Michael John on Mar 3, 2009 19:10:56 GMT -5
There are companies which supply inlay materials to luthiers, and they charge a FORTUNE for inlay blanks, to the tune of $25 to $50 an OUNCE, depending on the particular material. Since the shells are rounded, the first step would have to be grinding them until they're relatively flat, and then grinding them down until they're a little thicker than the desired thickness. The next step would have to be sanding down to the desired thickness, and making them smooth and polished. If I remember correctly, abalone gives off toxic dust when it's worked. I THINK a respirator is supposed to be worn. Unless he's going to do a LOT of inlay work, the cost of tools and the time it will take him to make his own stock from shells may not be worth it. Here's a link to a very reputable luthier supplier: www.stewmac.com/shop/Inlay,_pearl.html
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Post by texaswoodie on Mar 3, 2009 20:41:40 GMT -5
I just looked at the prices in that link and thought they are darn reasonable.
Curt
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Post by Woodyrock on Mar 3, 2009 23:13:50 GMT -5
Abalone MUST be worked WET! Seeing what the luthier suppliers charge, and having an idea of what is involved to make the inlay pieces, buying Chinese manufactured material is the less expensive route. The Chinese have been making sheet abalone material for a number of years from pieces that looks pretty damned good, and works well to boot. To thickness sand ab pieces, glue it to a substrate material, sand to desired thickness, then unbond from the substrate. Woody
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Post by Bikerrandy on Mar 3, 2009 23:54:51 GMT -5
If I remember correctly, abalone gives off toxic dust when it's worked. I THINK a respirator is supposed to be worn. That's an understatement, that stuff can kill ya!! I did a thread on it somewhere. There was a guy that opened a shop that specialized in it. 3 of the 7 people that worked there died from that stuff, very dangerous!
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Post by Bikerrandy on Mar 4, 2009 0:00:16 GMT -5
Here's a cut and paste......
The dust created through the grinding and cutting of abalone shell is dangerous; appropriate safeguards should be taken to protect a person from inhaling these particles. An N95-rated dust respirator, a ventilation system, and wet grinding are requirements to working the shell safely. The calcium carbonate is a respiratory irritant and the particles can penetrate into the lower respiratory tree and cause irritant bronchitis and other respiratory irritation responses. The usual symptoms are cough and sputum production, and secondary infections can occur. If there are proteins left in the shell matrix, it is also possible that they can trigger an allergic (asthmatic) attack. In general, the more someone is exposed to something that triggers their asthma reaction, the larger the reaction. Allergic skin reactions can also occur.
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Post by Jack ( Yorkshire) on Mar 4, 2009 4:11:31 GMT -5
Thanks Randy I will remember that
John,
I dont know if it would work or not but I have a friend who works Horn for walking sticks he boils the horn to bend it would this work ?
When cutting the shell it smells the same as cutting Horn.
Just a Idea.
Jack Yorkshire uk
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