I found this article in the Spring 2023 issue (number 148) of American Lutherie. According to the article, this is an instrument that was one of the two predecessors to the modern ukulele. Built by a Portuguese furniture maker named Manuel Nunes who came to Hawaii in 1879 to escape the famine on the island of Madeira, this instrument, called a Rajao, was probably built in the 1880's and was recently (and expertly) restored by the articles author, Karl Hoyt. I build ukuleles and mandolins and was so intrigued by the article that I decided to build one myself. Having no dimensions available, I traced the body shape from the picture onto a CAD drawing using a series of arcs. The article noted the Rajao was similar to a modern day tenor ukulele. A tenor ukulele has a scale of 17", so that was what I used as a baseline to proportion the rest of the instrument. I sent an email to the author with the hope he would respond to a few questions I had about some other details. I was pleasantly surprised he responded the next day and said he could probably get some more details from the current owner.
In the meantime, I'm working on some test pieces for the inlay details. This is a test piece for the center strip inlay.
The light wood is one piece laser-cut from 3mm thick Baltic Birch plywood. The darker stuff is mystery wood bits also laser-cut and pressed into the cavities. I think it looks pretty close to the original. For the actual build, I'll probably use Tulip wood for the light stuff, Canary for the medium and Black Walnut for the dark. I have a stock of all those and all get along very well with the laser.
Also trying to decide which material to use throughout the rest of the build. The original was made of Koa because that was available in Hawaii at the time and was far cheaper than importing any other wood. Koa has since become the preferred material for Hawaiian ukuleles and is of course much more expensive.
So, do I try to keep the reproduction as close to the original material wise, or do I mimic Mr. Nunes and build with what I have on hand? Hmmm. I guess if I mimic the original builder, I shouldn't use power tools....
i regard anyone that can create a musical instrument on the highest level of woodworking. id say no need to keep it original, use what you have and are familiar with. it's not the wood, it's the expertise in the creation that matters for me ! you sir show that expertise. i look forward to seeing this come to fruition !
working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.
What a great read this was, and good on you for making your own journey out of it. Judging from your past work I'm sure it will be quite functional, and a thing of beauty. As always, thanks for sharing.
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