Very Early ZB Custom - Restoration

[Eric Dahlhoff]

Hi ZB fans. Last Dec. I acquired a very early single neck ZB project. The previous owner had done a nice job refinishing the body, but never got the time to put it all back together. So, even though I had sworn off any more "projects", I couldn't resist
This one has stamped R.A.L. SER#11 on the changer end. It's been discussed here on the forum a few years ago. I'm very sure it was originally built as a C6 since it had 6 pedals and possibly one knee. The pedals were located in the middle of the body. Although it has the "normal" yokes for the pull-rods, the pulling mechanics are pretty different and more complicated. It's a fascinating bit of history to me, to see how the early design was; what stayed and what changed.

ZB11-1.jpg

ZB11-sernum.jpg

ZB11-bellcranks.jpg

Somewhere in it's life 2 of the pedals were sawed off. Why sawed? Why not just removed? Seems kinda harsh. I tried to find a couple to match, but no luck. So I'm rebuilding it as E9 with 4 x 4. Moving the pedals over to the left.

The changer, though, is of a type I've never seen before. Much more complicated and obviously hand built. I took me a bit of time and experimentation to figure out how it's suppose to work. Forum member and ZB fan Brian Lee helped me a bunch. He also found pictures of another ZB on the forum with the same changer.

ZB11-changer.jpg

What would we all do without this forum??

[Taylor Kropp]

This is so cool Eric!

[Eric Dahlhoff]

Thanks Taylor - I hope you're enjoying your ZB!

Here's some detailed pics of the changer in this early version. Notice how all the parts are hand-made out of aluminum.

2 fingers.jpg

changer finger other side.jpg

The raise & lower pieces have different sized slots. They can be stacked for 2nd pulls on both raise & lowers.
The tuning screws are normal male threaded bolts, unlike "normal" ZB's which have a female thread.
(The rods on the left are just to show where the pull-rods attach.)

ZB11-single finger.jpg

The raise ends have little springs attached, which took me a good while to figure out.
They provide friction to keep the raise tuner screw from moving, and keep the finger lined up. The lowers don't seem to need that, and do not have the hole to attach the springs. The lowers are held against the endplate by the lower-return springs.
You may have noticed in the earlier pic that the lower-return springs are NOT adjustable.

raise springs.jpg

raise rod end.jpg

[Brian Lee]

Hi Eric, It's so great that you are posting the details of what you are finding on that early ZB you're working on, and thanks for the nice comment on my minor contribution in comparing notes on the changer function. It's really fun to see such an early example in Zane's series of ZB design iterations. That is one very cool rig!

I'm curious to hear how you find it plays after you get it all refurbished. While the lack of adjustable return springs is not so cool, that early changer design seems like it has some really nice features. The male thread adjusting screws seem like a plus- easy to procure! The little springs on the raise pulls are odd, but seem like they would work well to keep the tuner screws in adjustment without damaging threads. It's also cool how the pull rods are a "double shear" pull on the finger so they pull without any lateral twist, as opposed to the later single shear spokes that create some twisting force. Seems like it will play and sound great once you get it cleaned up and dialed in!

You sure do great work resurrecting ZB's, and your posts are really insightful! Thanks for sharing!
Great to see the details of another of your rebuilds!