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New Build: Metal Body Resonator

Here is a photo of my latest project. It is a metal bodied resonator. The body is constructed from 26 gauge sheet metal (Home Depot special). The neck is hard Maple with a Walnut fret board.

This is my second resonator project and my first metal body. Learned a lot about shaping and connecting sheet metal.

How does it sound? Exactly how you would expect a metal bodied biscuit resonator to sound. Slightly metallic and very loud.

Fun project.

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Replies to This Discussion

Permalink Reply by Taffy Evans on December 20, 2016 at 1:39pm

Wow what a challenge, well done. How much will the chrome plating set you back? Ha.

Permalink Reply by Tom T on December 26, 2016 at 9:28am

I course sanded swirls into the top and back, then "fogged" some dark gray metallic paint so the swirls peek through. Don't plan to have the body chromed.

Permalink Reply by Paul Craig on December 20, 2016 at 7:08pm

Looks great. Did you weld it together?

Permalink Reply by Tom T on December 26, 2016 at 9:32am

I did some test welding, brazing and soldering. Finally decided that solder was the most controllable approach. Took around a pound of solder (including the waste). I filed and and sanded the solder after it was together. A little additional solder fill and it looked good.

Brazing worked okay, but welding such thin metal caused a good deal of warping (even with a #0 welding tip). Soldering is strong and basically no warping.

Permalink Reply by Paul Craig on December 26, 2016 at 8:18pm

The solder will probably come apart on you soon with all the vibration and not sticking well to steel, it works best with copper due to the surface texture and lower heat. I would recommend brazing with silver solder or brazing with brass.

Did you use a brazing tip or just a regular torch tip?

A small brazing tip will help keep the heat to just the area getting brazed. Tig welding would be good or use a mig welder and spot weld to keep the heat down.

Permalink Reply by Tom T on December 27, 2016 at 1:08am

Thanks Paul.

As with most things, time will tell. I think the zinc coating on the sheet metal will help with the solder bond. I have a small jeweler's torch (The Little Torch) with very small tips available. I like the control it gives.

Several of the DIY metal bodies I found with a google search were soldered, so hopefully, thing will be fine. I'll keep things posted as the guitar ages.

Permalink Reply by Paul Craig on December 27, 2016 at 7:54am

I hope it holds too, I know that had to be a lot of work.

Permalink Reply by Tom T on July 12, 2017 at 11:28am

So far, so good. I've been playing "MetalBody" on a daily basis now since December. No signs of cracks or failures of the solder. I'm fairly confident that well executed solder joints are very strong and will hold up for a long, long time. BTW, I just love this guitar. The Reprogle cone sounds amazing and in open tuning with a slide it is all old school. Great project.

Permalink Reply by Paul Craig on July 12, 2017 at 9:30pm

Great to hear. Glad your enjoying it.

Permalink Reply by Paul Craig on December 26, 2016 at 8:23pm

Another method you could do would be using JBWeld. It sticks to metal and it's sand-able and takes paint well. Holds up good too, my Dad used it to seal a hole in a engine block once.

Permalink Reply by Tom T on December 27, 2016 at 1:09am

I've used JB Weld. it really is good epoxy based stuff. If the solder doesn't work out, I think brazing would be plan B.

Permalink Reply by Paul Craig on December 27, 2016 at 7:57am

I used to do a good bit of silver soldering back in the 90's. Love that stuff, told myself that I would never again braze with brass rod. It is a little more expensive though and not as easy to find.