Making
the bentside is quite an elaborate operation. There was a time when I steamed
solid 5/8-inch thick planks of wood and forced them into the approximate
arc I desired. This was labor-intensive, and prone to problems like breaking
boards with a sudden and heart-stopping "CRACK!" For many years now I have
laminated my bentsides from 1/8-inch-thick slices of whatever wood was
being used to make the instrument. The thin sheets of wood are glued and
registered on a form, and clamps are applied until the glued is well set.
This makes for a very strong and stable bentside of predictable curvature,
and has vastly improved my instruments.

While
the benside is curing I go to work marking out the cuts to be made in the
cheek and spine - the right and left sides of the harpsichord. These cut
are critical to the true alignment of the case, and must be dead-accurate
- the cheek has to be a precise mirror image of the spine. I use a router
to cut the dovetail slots and wrestplank mortices. I have a love-hate relationship
with my routers - they are noisy, extremely dangerous, have a life of their
own, but they are also very efficient and good at what they do. So there
you are.
Throughout this process - the milling, planning, cutting and joining, I have accounted for the characteristics of the wood. Since wood moves with changes in humidity and tension, I have to plan ahead, anticipating how the instrument will deform when it is strung up and out in the real world.
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casework
Once
the dovetails are cut and the mortices routed, I trim up everything with
a very sharp chisel, making the corners square and trimming off bits of
wood fibre left behind by the router's carbide bit. Then it is time to dry-fit
everything, to see that it goes together as planned. Because the nameboard,
belly rail, lower belly rail and wrestplank all fit in either sliding dovetails
or mortices, I can assemble this end of the instrument without benefit
of glue, so I can check its alignment and mark out all the other joints
of the case walls.

Once
I am satisfied that everything is in order, I go ahead and glue the tail
to the spine. This is a convenience, in that once I have completed the
next step, eveything will be in place to fit the bentside. So having attached
the tail to the spin, I go ahead and glue together the cheek, nameboard,
wrestplank, and belly rails to the spine. The dovetails, including the
keyed dovetail holding the belly rail in place, hang the case together
while I apply pressure with clamps. Not too much pressure, because I don't
want to starve the joint of adhesive.
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© David Jensen 1998