Factory Tour
Wood & Lumber Selection
Curly (Tiger) Maple Logs Waiting to be cut.
One of our suppliers preparing to section a Tiger Maple log with a chainsaw.
Sawn in Half, it will yield Quartersawn Maple Blocks for Top & Back Sets
Maple Blocks Waxed, Stacked & Graded for Top & Back Sets
We have a tremendous selection of fine air & kiln dried Instrument Grade Tone Woods to choose from.
All woods for Smith Basses are acclimated for years before being used.
This stack of Eastern Black Walnut was slab-cut with the bark still on it. I asked the supplier not to square the boards. This way I have more room to play with the figured sections.
This stack of Claro Walnut is for Top & Back Sets. Some pieces are 24″ wide by 3″ thick.
End-coating a block of Walnut with ‘Anchorseal’ Wax. This will prevent the ends from splitting as the piece air dries & acclimates.
Walnut & Maple Blocks are waxed & stickered for air drying in these shelves. The Ebony lumber in the middle/right shelf will be cut for Elite Model tops.
I just had to crawl up here to see how much wood I’ve stacked in this room.
Here I am doing crunches with a Tiger Maple Block. This is not my normal daily exercise!
This room is used for Air Drying Maple & Walnut Blocks. They are waxed & stickered for long term storage. The un-stickered wood on top is already dried and is used as dead weight to prevent excess movement.
With several years worth of Figured Maple & Walnut already dried & in stock, the wood in this room will not be used for several years.
Tiger Maple Lumber stacked for air drying as of 6/29/1999. It will dry & acclimate for several years before we use it for Body Parts
This stack of Tiger Maple is Dated 3/23/2000 and will not be cut till earlier shipments have been used. Our vast Inventory of Lumber ensures you will get the best aged woods available.
This 6ft section of Tiger Maple will yield a BSR ‘M’ Model Body Wing Set as well as a ‘BSR’ Top & Back Set for Laminated Models. Layout is important for yield conservation. Good wood is hard to come by, therefore I personally stay involved in all stages of production.
This 2 piece Tiger Maple Set is for our BSR ‘J’ & ‘M’ Models. Each half is wider than our standard body wings because there is no center block.
This slab of Figured Claro Walnut is 10′ long x 24″ wide. It will take quite some time to lay out this valuable board for optimum yield.
These pieces of Highly Figured Claro Walnut are reserved for Elite Models only. Some of these will make Exhibition grade Tops.
These Figured Walnut pieces are being selected for Black Tiger Models. Existing Body Wings sets are used as grading samples.
Body Wing Sets & Bolt-on Bodies in our storage room. These are some of our most popular models. We’re always 1-step ahead in the aging & acclimation process.
All Fingerboard blanks are properly seasoned in our wood room before being used on a Smith Bass.
All Fingerboard blanks are properly seasoned in our wood room before being used on a Smith Bass.
Dated neck billets are stored in this rack after glue-up (3pc, 5pc, etc.) Some necks sit for years before being used.
Necks are selected for production as needed. The oldest necks are used first.
That’s Right! No Smoking in this room or anywhere else in the building for that matter! Besides, it’s bad for you & everyone around you, especially children.
“SO DON’T SMOKE!!”
A Public Service Announcement Sponsored by Ken Smith Basses, Ltd.
Shop & Machining Operations
KSB Machine Room. Cutting and machining of Neck parts and Body parts is done in this room.
A 5 Piece Body Wing dissection (Top, Back, Core, & Laminates). All Laminates (Veneers) are 4 Piece matched sets, resawn from top & back woods. (Standard on Elite Models)
Body Wings being joined just before gluing Features on.
Body Wings being sanded to final thickness before glue-up.
Joining the Center Block.
Center Blocks being sanded to final thickness.
Selecting the Center Block. They are matched up with Body Wings to make a bolt-on Bass.
Each Body is sprayed with quick drying naptha to simulate what it will look like when oiled.
Leveling & squaring the Body Wings before gluing to the Center Block.
Gluing up Body Wings to a Neck.
Gluing up Body Wings to a Neck.
Gluing up Body Wings to a Neck.
Gluing up Body Wings to a Neck.
This ‘dough roller’ takes out the machine marks and prepares the body for carving.
Routing the neck pocket in a bolt-on Bass.
These glue presses were made here at KSB. We glue only 1 neck billet at a time. Billets will yield only 1 or 2 necks. This method ensures a tight glue line.
Fitting the graphite reinforcement bars in a Neck Billet.
Cutting the truss rod slot.
Cutting the truss rod slot.
The truss-rod is inserted into the neck.
Routing the headcap for the Smith “S” inlay.
The ‘Coat of Arms’ is being cut into the rear of the Headstock. This is a Classic Smith Trademark.
The Fingerboards are cut on our custom gang saw. All 24 fret slots are cut in one operation.
The Fingerboard is rounded where it meets the Body. Then it gets glued to the Neck.
Then the fingerboard is fitted for glue-up.
The Fingerboard is glued & clamped to the Neck. It will sit overnight as the glue dries.
“End of the day sweeping” A clean shop keeps workers Happy and Healthy.
Handcarving & Finishing
This is the Carving Room where all Smith Basses are hand-carved into a work of art. Each Smith Bass is a one-of-a-kind. No two are exactly alike.
Neck-thru Basses ready for Hand Carving. (6GN Tiger Maple & 5GN Bubinga)
The Figured Exotic Woods of our bodies must be shaped and sanded smooth. Everything must look and feel right.
Hand squaring the Bolt area of the Neck.
Every bolt-on neck is individually hand-fit to the body.
Blending the Neck into the Headstock by Hand.
The final shaping of the neck is done “The Old Fashioned Way, by Hand!”
Hand fitting Maple strips for a Lined Fretless
Gluing them in.
Fitting the Pearl dot inlays in the fingerboard.
Fitting the Pearl dot inlays in the fingerboard.
The fingerboard is leveled and radiused in preparation for fretting.
The fingerboard is leveled and radiused in preparation for fretting.
Installing Frets with an Arbor Press.
Blending the Body Wings to the neck “A Delicate Operation.”
The Mother of Pearl “S” inlay being fitted into the headstock.
The Mother of Pearl “S” inlay being fitted into the headstock.
Hand shaping the Headstock.
Final oil sanding a 7-String Bass before lacquer finishing.
After all the carving is done, the hand rubbed finish begins.
Then each Bass gets several coats of Smith Dutch Varnish or Catalyzed Lacquer over Stradivari Gold oil. All Smith Basses are hand buffed when completed.
Then each Bass gets several coats of Smith Dutch Varnish or Catalyzed Lacquer over Stradivari Gold oil. All Smith Basses are hand buffed when completed.
Hand polishing the catalyzed lacquer finish.
Cleaning the fret edges after being lacquered.
Hand polishing the frets during final rub out.
Setup & Final Assembly
Cutting the Bridge prior to installation.
All Smith USA Basses come standard with the Smith 3-Band EQ circuit (5 knobs).
All Smith USA Basses come standard with the Smith 3-Band EQ circuit (5 knobs).
Smith Custom Pickups and Hardware are then assembled to the Bass.
Each nut on the Bass is filed and shaped by hand to fit that particular Bass.
Every Bass is checked by Ken before it goes out.
The truss-rod cap is fitted and backplate is signed and dated by Ken.
Ken starts every Bass and he also finishes it. The serial # is stamped into the fingerboard under the 24th fret.
Final adjustments are made before taking a BSR 5GN in Tiger Maple for a test drive. ‘Fasten your seat belt.’
Boy! It really feels and sounds great! Where’s the brakes? I can’t stop!
Smith Polish, Smith polish cloth, Smith strap with strap locks, & Wrenches.
Pack it up. “Hey Guys! Next time you’re going to take pictures, let me know – I’ll dress for the occasion.”
Don’t forget the Smith Strings.
Running a company for over 20 years is not easy. I used to have a full head of hair.
Workin’ off the stress! “I think I’m being watched.”