A Pictorial Review
by
Ken & Trisha Brooks
This Baystate banjo (1865-1897), sold by John C. Haynes & Co., Boston; came into our store for repair of a broken peghead.
We thought you might like to see how the repair was done.
Click any picture for a larger view
![Overlay pieces](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-overlay-pieces_small.jpg?6071994668472915289)
The overlay wood was so dry that it crumbled while being removed. The inlay was saved to be put in the new overlay.
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![Pedhead and inlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-head-no-overlay_small.jpg?6071994668472915289)
The front overlay piece had to be steamed & pried off.
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![The break glued and clamped](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-glue-break_small.jpg?15047864182564343766)
The break glued and clamped.
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![Back view of clamped break](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-back-view-clamps_small.jpg?15047864182564343766)
The back view with a block screwed through peg holes for orientation of the new overlay. Keeps it from slipping while being clamped.
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![New rosewood overlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-new-overlay_small.jpg?17850070924098964204)
The new rosewood overlay glued and clamped.
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![Back of overlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-overlay-backview_small.jpg?7798396355828538966)
The back stripe wood was also damaged and very dry. It will need to be filled with some pieces that were in a plastic bag in the case.
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![New overlay trimmed](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-trimming-overlay_small.jpg?7748931128869124313)
The new rosewood overlay had to be trimmed flush to the peghead.
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![Trimming overlay on peghead](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-overlay-trimming-back_small.jpg?14428644074801621947)
Here you can see where the overlay needs to be trimmed to the curves and angles of the headstock.
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![Drilling peg holes](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-drilling-peg-holes_small.jpg?9305972880052821577)
The pegholes were drilled from the back through the new overlay then they were chamfered on the front side by hand using a countersink bit to fit the friction pegs.
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![Inlay trace](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-inlay-trace_small.jpg?1398254043043837840)
Next the old inlay was traced onto the new overlay.
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![Routing for inlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-routing-inlay_small.jpg?14428644074801621947)
A hole has been routed using a fine bit in a Dremel router.
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![Clean hole for inlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-inlay-rout_small.jpg?11305042173929110033)
Clean hole cut to the depth of the old inlay.
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![Very thin inlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-inlay-fit_small.jpg?2814406729202096496)
The inlay is so thin that it had to be set to a perfect depth. There was no extra to sand down.
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![Inlay glues and weighted](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-glueing-inlay_small.jpg?2688056089541138568)
The inlay was glued & weighted.
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![Inlay edges filled](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-inlay-fill_small.jpg?6350889743098858969)
And of course it had to be fille with this yucky business. Not to worry.
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![Inlay finished](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-inlay-clean_small.jpg?18265091778090759849)
A little scraping & cleaning and it's good as new.
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![Fixing back stripe](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-damaged-backstripe_small.jpg?14408126534995627531)
The dry and brittle wood of the back stripe was missing pieces. You can see some saved pieces in the plastic bag.
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![Glueing pieces on neck](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-glueing-back-pieces_small.jpg?11037698139922736735)
Some large pieces were glued in and taped until dry. More voids had to be filled with glue and ebony wood dust.
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![Fitting the nut](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-refitting-nut_small.jpg?15075067600768040365)
The nut was refit into the overlay at the proper depth.
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![Preparing to refinish side](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-prep-side-stain_small.jpg?15315247029088191474)
The neck was taped off in preparation for staining the side of the peghead.
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![Staining overlay](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-staining-overlay_small.jpg?11768857540090638399)
The overlay also needed stain.
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![Oiling fingerboard](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-stain-oil_small.jpg?2967116925429526510)
The dry fingerboard was oiled to prevent cracking and fret protrusion.
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![Banjo pegs reinstalled](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-reinstall-pegs_small.jpg?2669859934791521699)
The pegs being installed in their respective holes.
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![Parts put back together](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-reassemble_small.jpg?10037904472335422378)
Time to put the parts back together.
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![Everything done](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-secured-neck-stick_small.jpg?13230419690430941415)
The hardware securing the neck stick to the pot. All the shims were put back in place so the action would be correct.
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![Side view of finished peghead](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-sideview-peghead_small.jpg?6071994668472915289)
The peghead side view of the repair
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![Finished banjo peghead](https://cdn.shopify.com/s/files/1/0985/0360/files/banjo-finished-peghead_small.jpg?6071994668472915289)
The finished peghead with a couple coats of lacquer for beauty and durability
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This Baystate banjo is the first I've seen with a set screw built into the fifth string peg to keep it tight. Over the years, the hole had become enlarged and needed fixing so the screw would do its job.
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A new set of strings and reattaching of a case hinge and this old timer is good to go.
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