A custom beauty
by Jim Olson.

Photo by Dana Wheelock

 

 

 

Custom Guitars

Five makers' approaches to
building a customer's
dream guitar

 

Michael Hornick
Marty Lanham
John and Bill Gilbert
Steve Grimes
James Olson
Sidebar: How to Shop for a Custom Guitar

When guitar makers get together these days, the talk often turns to the Golden Age of Lutherie. That age happens to be taking place right now, and we who are in the field of fretted instrument building, repair, and restoration are in the incredible position of knowing that we are living in the good old days. There are more good builders with access to excellent parts and woods and useful information on the craft than ever before. Dozens and dozens of luthiers are making a wide variety of beautiful guitars in everything from one-person shops where just a few instruments are made each year to factories where scores of guitars are built every day. However you look at it, there have never been more high-quality choices for the acoustic guitarist.

The phenomenon of the individual luthier—especially for steel-string guitars—is a relatively recent one. In the first half of the 20th century, American flattop guitar making was dominated by big factories. By 1960, Gibson, Guild, and Martin reigned so supreme that it was thought that an individual just couldn’t make a guitar as good as the factories could. Even in the field of archtop guitars, hand-builders such as Stromberg and D’Angelico were few and far between.

In the 1960s and early ’70s, luthiers such as Eugene Clark, Michael Gurian, J.W. Gallagher, Stuart Mossman, and Roy Noble started to build guitars individually in small shops—basically making up the craft as they went along. With only two very hard-to-find books on guitar making available, many of these pioneer modern luthiers had to take instruments apart to find out how they were built.

Today there are so many books and videos on guitar making and repair that I can’t keep up. There are two separate guitar makers’ organizations and quite a number of schools and courses specializing in lutherie. Guitar making in small shops is now a viable profession for the dedicated craftsperson. For some—such as Santa Cruz, Breedlove, Collings, National Reso-Phonic, and Bourgeois—the goal is to build up small "boutique factories." The employees at each of these companies turn out 40 to 60 instruments per month.

The subjects of this article, however, all work in very small shops with little or no help. Outputs range from fewer than 12 guitars per year (Michael Hornick) to a nearly superhuman 60 instruments per year (James Olson). All of these makers work in well-organized spaces, and each luthier has also mastered the art of building the specialized jigs and fixtures that aid precision work. Several of them have past or current side careers as working musicians, a factor that certainly affects their approaches to designing and building instruments. Keep in mind as you read these profiles that this handful of makers was chosen as a representative sampling of the hundreds of individual luthiers working today; check out scores of custom makers in our online Custom Guitars Gallery and Luthiers Directory. You'll find additional makers in our online Manufacturer Directory. Next time you’re shopping for a guitar, consider that there’s probably a world-class guitar maker within a couple hours’ drive of your home.

—Rick Turner

MICHAEL HORNICK
AVERY, CALIFORNIA

"It’s the neatest woodwork on the planet." Michael Hornick’s eyes twinkle like those of a guitar-making Santa Claus as he shows off the shop where he builds nine or ten guitars a year under the Shanti name. "There’s nothing that compares to the finished product of an instrument. It’s alive, and it’s so much more than just a piece of woodwork."

Hornick considers himself a true custom builder. "It’s not just offering custom options," he says. "For me the ultimate thing in building is to have players come to my shop, to sit down and listen to them play, and then absolutely zero in on their taste in every aspect of the instrument, whether it’s some far-out new kind of inlay or just the purfling that goes around the top. So it’s two people’s creativity going into the instrument, not one." Hornick pulls out a few examples of his exquisitely detailed work. "Every rosette is different. You wouldn’t believe the stuff we come up with sometimes. Until it’s right, I can’t stop."

Hornick’s obsession with detail is evident. "I do an awful lot of stuff inside the instrument: interlocking braces, laminated bridge plates. . . . It takes time to do that little bitty stuff, but that’s the thing that drives me: can I make it better? I’d like to think that my instruments will end up having a real life span. Not 50 or 100 years, but hopefully hundreds."

This high level of craftsmanship is one reason you will find Shanti guitars in the hands of players like Pat Flynn, Peter McLaughlin, and Lorin Rowan. Another reason is the sound. "I’m such a tone freak," Hornick explains. "It’s easy to get a big bottom on a guitar. It’s a whole different ball game to get the midrange just as sweet and thick. On the really good-sounding guitars, when you hit a treble note it pulls out all the bass overtones that are sympathetic to it. What makes that aliveness and effervescence in the tone is when it’s pulling out its opposites. You get it from both sides; it doesn’t just come from one place."

Hornick says that "a master luthier can make a really good-sounding guitar out of most any piece of wood, [but] they’ll make a great-sounding guitar out of a great piece of wood." Which is why he gets so excited about tonewoods. "I just go nuts over the woods. This [he gestures to his wood storage closet] is my playroom, my favorite room." He points to some stacks of wood. "That’s silver spruce from the Black Forest. Right now I’ve got 35 German tops that are to die for. I can remember way back in the ’60s when you got your little baggie and it was like, ‘I got my stash.’ That’s the way I feel in here all the time. I’ll call [a luthier friend] and say, ‘I got a real good score for you’ and start laughing. We actually relate it that way sometimes." He pulls out another piece. "This is some gorgeous yellow spruce. Put your nose on the end and smell it."

One way Hornick shares his knowledge of lutherie is through a mandolin-building course he teaches each year at the RockyGrass Festival in Lyons, Colorado, and again in his own workshop. "In four or five days, you get the experience of building an instrument," he says. "The students do their own fretwork, they carve their own necks, they put everything together. They don’t bend [the sides]. I cut the ledges for the purfles and the bindings, but they glue them in and scrape them down. One of the things I want to make sure people get in the class is the freedom to be artistic. It’s real fun because all the enthusiasm and everything that’s going on, as well as the process, is shared. They walk away in a whole different place."

RockyGrass is but one of the many festivals Hornick attends. Each year the winner of the Troubadour singer-songwriter competition at Telluride walks away with a Shanti. "Telluride has been really good because everybody knows me; I’ve been a part of the festival forever," he says. "The big deal for me is staying in touch with the people and the players. Most of my orders come that way rather than through the mail."

He recently completed guitar number 77, but Hornick still remembers the thrill of his first instrument. "Guitar making was the avenue for my artistic [impulse] to come out. With the guitar, I just never got tired of doing it. [The first one] took a year and then it was alive. And when I strung it up, I knew that this was it, this is what I was trying to find. Ultimately the whole thing was finding the passion and having the opportunity to go for it. I consider myself unbelievably fortunate."

—Phil Campbell

MARTY LANHAM
NASHVILLE, TENNESSEE

The two-room barn next to Marty Lanham’s house in Nashville is filled with stacks of wood he’s collected over the past 20 years. In his workroom hang the bodies of three freshly finished guitars, one of which will be first prize at the Cross Country Trail Ride in Eminence, Missouri. Holly Tashian’s Martin waits in its case for a fine-tuning before accompanying her on a European road trip. On the walls, photographs of bluegrass icons such as Bill Monroe and Dave "Stringbean" Akeman share space with the Beatles, Albert King, and Paul Simon. Lanham points out one of his favorite photos, which shows a young Johnny Cash smiling and chatting with Lester Flatt and Earl Scruggs.

Lanham’s Nashville Guitar Company services some of acoustic music’s most respected talents. He’s made instruments for Pat Enright and Stuart Duncan of the Nashville Bluegrass Band, mainstream country artist and former bluegrasser Marty Stuart, and songwriter Dave Gibson, formerly of the Gibson-Miller Band—as well as doctors, lawyers, overseas collectors, and other part-time players, including actor/banjoist Steve Martin. Lanham has been a professional musician for the better part of the past three decades, and his guitars combine modern adaptability with a traditionalist’s appreciation for acoustic instruments.

He got interested in instrument repair in 1964, when he brought a couple of his old Gibsons to a shop. "I took them to a place in San Francisco that was pretty reputable," he recalls. "When I got them back, I could see the guy’s handprint in glue on the back of the mandolin. I knew that I could do better work than that." As a teenager, Lanham had done plenty of gun-stock work, so he was no stranger to wood, and in the late ’60s he began working on instruments for friends and colleagues he met playing bluegrass banjo in the San Francisco area.

In 1972, the members of Lanham’s band, the Styx River Ferry, decided to move to Nashville. Lanham got a job in the repair shop of Gruhn Guitars, where he worked for eight years. "That’s where the bulk of my knowledge of instruments and materials comes from—the constant parade of the finest instruments in the world," he says. He also had the opportunity to work on Hank Williams’ old Martin D-45, now owned by Marty Stuart, Lester Flatt’s D-28, and two of Jimmie Rodgers’ guitars—a Weymann and a Gibson HG-24. Still, Lanham’s primary focus was on his musicianship, and he spent four years as banjoist on the Grand Ole Opry, playing with bluegrass legend Wilma Lee Cooper.

Lanham gradually began making his own instruments, and in 1985 he decided to devote himself full-time to the business of lutherie. "The musicians of this community have shaped what I do," Lanham says. "I like to work on instruments for people who play professionally, who push the envelope and push the instruments to the maximum demands of the road. I think the thing that’s unique about my instruments is not any one detail or feature, but the experience I bring to the workbench—experience with musicians, and experience gained from being a musician myself."

Lanham’s instruments are built with traditional tonewoods like rosewood and spruce as well as more unusual species like Tasmanian blackwood and Malagasy kingwood. "A big issue among instrument makers," he says, "is the supply of wood. We’re all looking for alternative woods and a sustainable-yield wood supply. I’ve located some people who specialize in wood harvesting. There’s a guy named Larry Trumble who seeks out individual trees in Alaska. There are a lot of trees, for instance, that were cut off about 15 feet above ground, so there all these 15-foot stumps."

How many hours does Lanham spend on an individual instrument? "I honestly don’t know," he says. "I work in a more organic way, I guess. I spend a lot of time not just out here in the shop but doing R&D, you might say. The [musical] genre really determines the demands of each instrument. Bluegrass players are mostly traditional-minded. They want a big body with a big, boomy sound to be heard over all the other instruments in a bluegrass band. A songwriter like Dave Gibson—who does a lot of demo recording, and generally plays electric on stage but likes to write with an acoustic—wants a smaller body with a more focused sound."

Lanham confirms that his instruments have gotten better over the years. "Sure, there’s been a progression," he says. "And there is a tremendous amount of information sharing—good, accurate information—within the instrument-building community. In the past five years or so, there has been a renaissance in the handmade instrument community. As a result, the craft as a whole has improved. We’re all making better instruments than we did 20 years ago."

—Shelton Clark

JOHN AND BILL GILBERT
WOODSIDE, CALIFORNIA

When I first talked to John Gilbert about interviewing him and his son, he asked, "Do I have to clean up the shop? Bill has got it full of machinery for his new place, and it’s a shambles." When I arrived at his house in the Santa Cruz mountains south of San Francisco, I saw what he meant. A two-car garage was packed with more than 30 years’ accumulation of tools and wood, with just enough wiggle room for access to a couple of workbenches. John, whom I had met before at luthiers’ meetings, welcomed me cordially and introduced me to his son Bill. We spent several hours talking guitar making and covered a wide range of topics from the technical to the aesthetic.

John built his first classical guitar in 1965, shortly after going to work as a tool engineer for Hewlett Packard in Palo Alto, California. A coworker showed him a slim volume entitled Make Your Own Spanish Guitar, and it seemed like a fun project. At first, building instruments was just a hobby for John, with a lot of repair mixed in, but by 1974 the response from players was so encouraging that he decided to build full-time. By 1991 he had made 140 guitars that were played by a long list of professionals including David Russell, Frederic Hand, Konrad Ragossnig, and David Tanenbaum, to name just a few. At that point, John brought his son Bill into the business to give himself more time to develop a line of guitar machine heads he had invented. Bill has now built 42 guitars under his own name, and John says proudly that customers tell him confidentially that his son makes better instruments than he did.

When asked for a description of the characteristic sound of a Gilbert guitar, John’s response is very direct. "It’s neutral," he says. "It responds to the way a guitarist plays instead of having a certain type of sound. Our guitars have a wide range of tone color, they project very well, and they’re very even on the first string. Above the seventh fret, where a lot of guitars poop out, they stay strong."

What about left-hand action? "Playability is critical," John says. "You can build the best-sounding guitar in the world, but if it tires you out to play it, it’s useless. We go to a lot of trouble to build a neck that is really stable, that will hold close tolerances, so that we can do really accurate fretwork. That lets us bring the strings as close as possible to the fingerboard without buzzing."

This kind of careful engineering and accurate measurement is evident in all of the Gilberts’ processes. If there is one word that describes their approach to making guitars, it is precision. John’s background as a highly skilled toolmaker carries over into woodworking. The stiffness, weight, and dimensions of the soundboard, the back, and all the interior bracing are measured and recorded for each instrument. All of these parts have to meet certain specifications that have been established by years of experimentation. It’s no wonder that Gilbert guitars have a reputation for consistency.

As John and Bill talk about the craft they so obviously love, they seem more like buddies than father and son. Good-natured banter is the order of the day. I ask Bill how they managed to transfer the business across the generations so smoothly. "My dad made it clear that I was either going to make instruments of the same quality that he did, or I wasn’t going to make them," he explains. With this goal in mind, Bill and John worked together for more than a year, cosigning the guitars’ labels during this transitional period.

If customer response is any measure of Bill’s success in taking over the construction side of the business, he is doing very well indeed, with a three-year waiting list to buy one of his instruments. He is currently building with East Indian and Madagascar rosewoods, and customers have a choice of western red cedar or any of three species of spruce for the soundboard. Bill continues John’s policy of satisfaction guaranteed. When customers receive their new instruments, they have a couple of weeks to try it out, and if they are dissatisfied for any reason they get a complete refund, including shipping costs. In over 25 years, no one has taken the Gilberts up on that guarantee.

—Brian Burns

STEVE GRIMES
MAUI, HAWAII

The road to Steve Grimes’ home and guitar workshop in the hills of Maui isn’t an especially winding one, but you have to look out for packs of cyclists coasting down from the Haleakala Crater, a popular activity among the tourists. Grimes and his wife, Joan Mercer—who describes herself as the only person in the world who makes a living creating arrangements of dried, tropical protea flowers—can put up with the inconvenience. In fact, Grimes deliberately came here from the mainland 15 years ago to enjoy the Maui lifestyle and escape a run-of-the-mill existence.

When Grimes left his shop in Port Townsend, Washington, he’d already been building instruments—mostly acoustic archtop guitars and mandolins—for 12 years. Although about half of the 20 instruments he builds each year are still archtop guitars, living in Hawaii has had a definite effect on his work. When Grimes met master slack-key guitarist Keola Beamer in 1987 and heard his double-soundhole flattops, he was inspired to design his own, differently braced version, and these instruments now account for about half of his work.

"Slack-key players often tune the low E string all the way down to C," Grimes explains. "By moving the two soundholes into the upper bout, you generate a larger surface area to reproduce such low notes. I sell a lot of two-soundhole guitars for standard tuning, too. They’re loud, and they sound a lot different than a Martin!"

Building archtops takes up about half of Grimes’ remaining time. He offers four models: the Kula Rose, the Jazz Nouveau, the Montreux, and the Laureate. He also makes the occasional Tiny Grimes mini-flattop, Bird of Paradise electric, or GS model. The GS, or Grimes-Steinberger, is a guitar he codesigned with Ned Steinberger that puts no string tension on the top, allowing it to be built very lightly and produce a lot of sound. "The stress-free design uses a tailpiece, and the strings’ break angle over the bridge is so lateral that there’s no stress on the top at all," Grimes explains.

Grimes' clients create an infinite number of custom guitars by choosing their instrument’s size, woods, finish color, inlays, electronics, and neck profile. "I enjoy getting into a real working relationship with a potential customer," he says. "I take a lot of time to explain to people what this model does that the other models don’t do. The Jazz Nouveau, for example, has a flat back, so it gets a little bit of that flattop guitar bass response that you don’t usually find in an archtop. I’ll ask them how hard they play. Do they like a high action? If they know what they like, I can duplicate or improve on that. I used to do repair work and had four or five customers a day, and I didn’t like that. Now I have 20 customers a year, so I really like the social interaction."

Yet Grimes enjoys working alone. "I don’t want to build 50 guitars a year and have five guys working for me," he explains. "You become a manager; your whole job description changes. The stress level would go up. If I’m in a bad mood [now], I’ll come in here and put on ZZ Top as loud as I can get it. That’ll change my mood."

Grimes builds his guitars in batches of a dozen, nearly completing two batches per year. Does building 12 guitars simultaneously make it more difficult to customize each one? "I used to build two or three guitars at a time, and I really enjoyed it," he says. "And I thought, ‘I would never enjoy the production-line type of building where I’m doing a dozen at a time.’ Until I tried it for the first time. And I love it, I really do. I’ll set up to do necks, and I’ll get out 12 neck blocks and all the little jigs and routers that I use. The procedure is the same, but I don’t have to keep setting up. What keeps it from being a production line is the fact that each one is different and each customer is different."

Despite his efficiency, Grimes’ enthusiasm for the work keeps him in the shop about 70 hours a week. "I work too much," he admits. "I have fairly regular hours, but they’re ridiculous hours. But I’m not really pushing myself. When I’m in here, I’m in a groove, I’m totally zoned out. And that’s low stress. After 25 years, I still can’t wait to get in here every morning.

"If I made guitars and they were being sold by a third party in a store, it wouldn’t mean the same thing," he adds. "I like the personal feedback." And it's the feedback he gets from his customers before he starts building that helps them get the instruments they want. "The most important question I ask them is, ‘Why do you want a handmade guitar? What do you envision it doing for you that your Martin or your Guild doesn’t do?’ Then I’ll tailor the guitar—the way it looks, the way it feels, the way it sounds—to what the person wants."

—Simone Solondz

JAMES OLSON
CIRCLE PINES, MINNESOTA

James Olson is one of those overnight successes who took 20 years to get there. After setting up as a full-time luthier in the late 1970s, he earned a reputation as one of the Twin Cities’ best builders. Then in 1982 he gained wider recognition when Phil Keaggy bought one of his guitars. Since then, other professionals have discovered the impeccable workmanship and distinctive sound of Olson’s instruments, and now you can see the large O on the headstocks of guitars played by Leo Kottke, Kathy Mattea, Paul McCartney, Sting, James Taylor, and David Wilcox, among others.

This high visibility means high demand (even with the new $3,595 price tag that went into effect in January of this year [1997]), and Olson’s current backlog is 100 instruments, which translates to an 18- to 24-month wait for a new guitar. Olson works 60-hour weeks with the assistance of a single employee, and his output is about 60 guitars per year.

The challenge for a luthier in Olson’s position is not figuring out how to make great-sounding guitars, but how to make them efficiently. "You have to [pursue sound] in the beginning," Olson explains, "because you’re formulating a sound that you want to reproduce." But, he adds, the range of individual taste and preference means that there is no single, perfect sound to attain, although each guitar must have excellent volume, intonation, harmonics, sustain, clarity, and balance. "After you get all those things happening, it’s a good guitar," Olson says, "and then you can chase it a little bit this way or that way if you want to."

What all of his customers want, Olson believes, is consistency. "This is the constant question: ‘How do I know that mine will sound like James Taylor’s or David Wilcox’s?’ They want it to sound like the one they heard. If you do something really different, then they don’t like it. Basically, I’m building the same guitar and finding out how to build it more efficiently, with less labor. That doesn’t mean that I’ve given up on making a better guitar, but what consumes me most is getting orders filled."

Olson works out of a barnlike former welding shop in a semirural area north of Minneapolis. He has extensively rebuilt the shop’s interior, and the lower level now houses the spray booth, buffers, and much of the heavier machinery, including a massive, industrial-looking thickness sander that Olson designed and built himself. This is also where his stock of wood is stored: book-matched sets for backs and tops, as well as piles of uncut rosewood, mahogany, spruce, cedar, maple, and walnut.

Upstairs, a spacious, well-lighted workshop and office is where most of the finer shaping and assembling is done. For most of his career, Olson has worked alone, and the shop walls are hung with tools, jigs, and clamps that he has devised to help him work faster and more efficiently. On one bench, for example, is a vacuum-operated rubber-and-aluminum device that allows all the braces for a top to be clamped at once in a single operation.

All these specialized tools point to the fact that a luthier is often a problem-solver and a toolmaker. "I don’t think there is a handbuilt guitar, actually," Olson says. "I use as many machines as anybody else, if not more. But my hands make the guitar in its entirety; it doesn’t take 50 different people to make the guitar. To me, handmade means smaller production, with one person building it.

"I don’t think that a machine does anything but make the guitar better. Anywhere I can use a machine to replicate something more efficiently and perfectly, that’s the object. And most of the time your hands are moving the machine anyway—instead of a chisel, you’re moving a router."

The other half of lutherie is taking care of business—buying supplies, keeping the books, and dealing with customers. During my visit, the phone seems to ring every few minutes. If Olson is in the middle of a task, he lets the answering machine pick up, but as often as not he takes the call himself and spends some time talking to a customer who wants to discuss the details of a dream instrument or trace the progress of a particular guitar.

Olson answers all the questions (including mine) patiently, but it’s not surprising that he likes to work at night, when the phones and journalists are quiet. In fact, he was up late the night before our interview, getting the kinks out of a new jig for cutting the ledges for binding. It’s still not quite right, though, and he is anxious to get it finished, because there’s a batch of bodies lined up, waiting for their binding.

After giving his assistant some instruction on trimming up sets of book-matched Indian rosewood boards that will become backs, he turns to his big Bridgeport milling machine and starts cutting and drilling the aluminum blocks that will hold and guide the router that will cut the ledges. When the jig is finished, Olson will set it up, do the cutting, and then move on to one of the hundreds of small operations that go into the making of a guitar. And at each stage, he will be looking for ways to improve the processes that make the guitars that make the music.

—Russell Letson


How to Shop for a Custom Guitar

by Rick Turner

Consider why you want a custom instrument.

Can you not find the right guitar in a music store? Are you after something really special? Having a custom guitar built will be a major commitment of both your time and your money. Learn what you’re getting into. Consider joining one or both of the luthiers’ organizations, the Guild of American Luthiers (8222 South Park Ave., Tacoma, WA 98408) and the Association of Stringed Instrument Artisans (PO Box 341, Paul Smiths, NY 12970). Read up on how guitars are put together so you can understand why a custom instrument might (or might not) be best for your touch and your music.

Find a luthier who already builds instruments like your dream guitar.

Don’t go to a classical builder for a dreadnought, and don’t go to a builder who’s only comfortable working with fingerstylists if you’re a flatpicker.

Check out the work of the luthiers you’re considering.

Ask for the phone numbers of people who own guitars built by the luthiers on your short list. Call the lucky musicians and ask how they like their instruments and how they liked the experience of dealing with the maker. Find out if you can play some examples of the builders’ work. You may be able to check out some luthiers’ guitars in retail shops.

Articulate your preferences.

At a minimum, most luthiers will want to know about what string gauge and setup you like, how you play (flatpicking or fingerpicking, hard or soft, style of music), whether you use low open tunings, etc. The more you can put into words about what you like in a guitar and how you’re going to use it, the more likely it is that you’ll get the instrument you’re dreaming of.

Be ready to be patient.

Custom builders often have long lead times (as long as two years), and those lead times can stretch.

Set a realistic budget, and consider how you want that budget apportioned.

You may be able to afford the Brazilian rosewood upgrade (often a multi-thousand dollar upcharge) but then be unable to afford the full abalone purfling treatment. Would you rather have a simple guitar with the very finest wood, or are you after something that will flash on stage? Don’t expect an individual luthier to build you the D-45 you always wanted for the price of a Baby Taylor. While going directly to a luthier does cut out a middleman, the individual builder will put a lot more hours into a guitar than a factory would, and small-shop overhead and tooling costs are often a higher percentage of total sales than those in a production shop.

Confirm the financial arrangements.

It is fairly standard to pay 50 percent up front and the balance on receipt of the instrument, but make sure that you’ve talked this through with the builder before he or she starts working. Also, check if a case is included in the price. Consider a Calton or Mark Leaf road case to protect your investment.

Discuss what happens if you are not satisfied with the instrument.

With some builders, you may be stuck; with others you can expect to get at least a partial money-back guarantee. Don’t expect a refund if the guitar has your name in lights up the fingerboard!


 

Excerpted from Acoustic Guitar magazine, August 1997, No. 56.

 

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