This post continues on from 1214: bergerault vibraphone (part 1)
The timber I bought is European Oak. I could have also used Ash, but that was not available. Both are known for their structural rigidity as opposed to the original timber, which is hidden behind a plastic veneer, but looks to be African Mahogany which is a cheap easy to use timber, which is not known for its strength.
After planing the timbers to size, I marked off the length and angles, to duplicate the existing note rails.
Because I am doubling the depth of the note rail, I put a double tennon at the ends to go into the end boards. This will massively increase the overall strength of the instrument. These outer rails are the only joints that hold the whole instrument together, so they must be good (unlike how they were).
Pictured above are the note rails with double tennons roughed out ready for the mortices to be dug.
Once All the new mortices were dug, I ended the day with a dry assembly to expose any problems.