Chapter One

What to expect - The basic building process, time and costs
&nb= sp;

Most prospective builders seem intimidated with this process.   None of the steps are that difficult – If anything, the hardest part for most folks seems to be those first two steps, buying (or scroungin= g) some lumber, then turning off the TV, going down to their workspace and beginning to make shavings.  &nb= sp; Believe me, building the harp will be much more rewarding than anyth= ing you end up watching on the tube.

The costs and efforts involved will depend on the tools you have, how persnickety you are about the fit and fin= ish of the different parts.   I will use two examples. <= /o:p>



Plain and Fancy. The harp on the le= ft is a simple 22 string harp, similar to the quick and dirty example discussed below.   The one the righ= t is a custom 36 string stave back in Curly maple with Bubinga piping between the staves and T-section on the pillar.

The first example is based on my th= ird harp, a little 26 string instrument that I built for my daughter so that we could begin harp lessons.    It was an experiment in quick and dirty harp building but turned out surprisingly well.   The = second example is a custom 38 string stave back in a fancy wood with all the bells= and whistles

Harp #3 a 26 string “quick and dirty”

Task	Materials/Additional Tools needed	Time (hrs)	Cost
Gather the materials, =	½ sheet of luan Plywood, a discarded maple bed frame	1	$6
Cut out the back, sides, top and = base for the sound box. Nail/scr= ew them together	Sabre Saw, Circular Saw, Drill, hammer, nails, Glue, Drill<= o:p>	2	$3
Make the string ribs, Glue them to the ply sound board	Circular Saw, Hand plane	2.5
Level the top of the sound box, nail/glue the soundboard into place	(No new tools, just the hand plan= e)	1
Trim sound board to sides of box<= o:p>	Coping saw& Sandpaper or Rout= er with trim bit	1
Laminate the Neck Blank from two layers of ¾” stock, Cut it to shape	5-6 Clamps	2.5
Drill holes for tuning pins, brid= ge pins in the neck	Awl, Drill press, drill bits, tap= ered reamer	2	$10 (reamer)
Cut out pillar<= /p>	Sabre Saw	0.5
Join neck to pillar with two dowe= ls and side patch	Dowel Rod	1.5	$2
Build feet	Sabre Saw, plane	1.5
Finish sand parts	Sand paper	3	$3
Bolt Neck and Pillar to sound box, screw feet to sound box	lag bolts, wrench	0.5	$2
Drill Holes for brass eyelets in = Soundboard	Electric Drill<= /p>	0.5
Apply three coats of finish<= /o:p>	Pint of Deft, Disposable Brush, F= ine 3M pad	1.5	$15
Mount Hardware	Taper Pins, Bridge pins, Eyelets,=	1	$45
String the harp, Tune it	Strings	6	$50

So the harp will take 28 hours of l= abor and cost $136 or so

Custom 38 string Stave Back=

Task	Materials/	Tools	Hours	Cost
Planning Gathering Materials
Lay out a design, Print templates		CAD program	10
Purchase Hardwood for Neck, Pillar, Shell	<= /p>	<= /p>	2.0	$150
Purchase Sitka= Spruce for Sound Board	<= /p>	<= /p>	0.5	$50
Order Levers, Hardware	<= /p>	<= /p>	0.5	$542
Order Strings	<= /p>	<= /p>	0.5	$90
	<= /p>	<= /p>
Sound box	<= /p>	<= /p>
Make the Jig for cutting Staves	Scrap Plywood, 1x2	Table Saw	3.0	$15
Make the Cradle for Holding Shell	Scrap Plywood, 1x3	Band Saw, Table Saw	4.0	$15
Fabricate Staves		Table Saw	3.0
Adjust cradle, Tape & Glue staves into shell	Packing Tape		2.0
F&I Bulkheads/Mid-brace		Band Saw, Stationary Sander	3.0
Fabricate Runners, Install			1.5

Cut Sound holes		Jig saw, Drill and drum sanders	2.0
Trim Bottom & Top		Chop Saw, Router	1.0
Fabricate Apron, Glue		Biscuit Jointer,	2.0
Level Face & route Channels		Belt Sanders, Router	1.0

Soundboard	<= /p>	<= /p>
Build Frame	Scrap 2x2	Table Saw, Chop Saw	0.5	$5
Plane SB planks		Table Saw Thickness Planer	1.0
Glue			0.5
Fabricate Ribs		Thickness Planer Spokeshave	2.0
Clean, Level & Taper the Soundboard		Power planer, random orbital sander	0.8
Glue ribs			1.5
Glue Soundboard		Bar Clamps	1.0
Trim SB		Router	0.5
Fabricate and edge batten	30 #6 x 3/4" Screws	Table Saw	2.0
Mount Inlay Strip		Router, Inlay Bit	3.0	$30
Glue veneer, scrape	Iron on veneer	Iron, Steel Scraper	2.0	$15

Task	Materials/	Tools	Time	Cost
	<= /p>	<= /p>
Neck & Pillar	<= /p>	<= /p>
Cut Neck and Pillar, Mark hole Centers		Band saw	2.0
Spline & Reinforce Neck			2.0
Drill holes for Tuning, Bridge Pins		Drill Press	4.0
Smooth Neck & Pillar		Edge Sander, Drum Sanders	1.3
Grind & Scrape Neck Recess		Grinder, Carbide Abrasive Disk	3.0
F&I Knee block (w/ dowels)		Band saw, Dowel Centers, Dowel	2.0	$3
Fit Pillar/Neck	Maple for Guide Jig,		1.0	$6
Drill & Glue	5/8 Dowels, Sock Jig	1.0	$6