On plastic
Tuesday, March 6th, 2007A popular-priced, high quality professional instrument

he act of substituting experimental materials for traditional ones in the process of string instrument building is as old as the craft itself. The gradual discovery and implementation of new and better tonewoods, appropriate uses of slab and bias-cut lumber, improvements in design, and gains in the sciences of physics and acoustics have all contributed to the constantly evolving creative act of luthiery. Interestingly, the motives for change are as varied as the changes themselves: popularity, availability of raw materials, new musical styles, old musical styles, demands of recording and broadcasting—or performing plugged-in or unplugged—improved sound and playability, etc. However, the one factor overarching all these is economics and the mantra that has driven mass production is to make things cheaper, faster.
Not surprisingly, cheaper and faster are rarely, if ever, better or even the same as traditional methods and materials. A central theme in marketing mass produced instruments, stringed or otherwise, is the creation of a myth—great sound and playabilty at a fraction of the cost—at odds with the convential wisdom that you get what you pay for. In 1946, plastic harmonica developer Finn H. Magnus claimed his polystyrene reeds were “just as resilient as brass” and produced “mellower tones” although the performer had to “blow a little harder for his music.” Harmonica virtuoso Larry Adler disagreed. “As a musician I couldn’t possibly use it,” Adler declared. “It does not have the necessary range of color and musical expression. The manufacture of the harmonica must be as painstaking as making lenses.” But at a tenth the cost of a Hohner, with six shiny colors to choose from and “making a noise likely to soothe anybody who likes the harmonica—except Larry Adler and his peers…” Well, you get the picture. Magnus reduced the number of parts to five and the assembly to one operation for his plastic mouth organ, compared to no fewer than eighty parts and one-hundred fifty operations for a simple Hohner Marine Band harmonica. His ingenuity paid off; it made him a millionaire.
The development in the first half of the 20th century of synthetic materials — plastics — which could be milled, molded, or drawn into virtually any shape, or designed for nearly any use, had a profound effect on the manufacture of objects in general and musical instruments in particular. Introduced into peripheral items such as tuning peg buttons and bindings, materials like pyralin, Bakelite and nylon were quickly expanded into use as integral vibration-transmitting parts like reeds, strings, and nuts and saddles, replacing cane, gut, wood, bone and ivory. While much of the development of plastics occured in the 1930s—most significantly, polystyrene and nylon—widespread commercial exploitaton did not take take place until after the Second World War.
In our own era change has been rapid and is nowhere more representative than in the ukulele family of instruments. Initially introduced into the Hawaiian Islands in the late 19th century, the forerunners to the ukulele (the machete and rajão) were constructed of woods native to the island of Madeira. Within twenty years of its importation the newly christened ukulele began to be made of Hawaiian hardwoods, most notably koa. Not only the backs and sides but the tops—traditionaly made of soft woods like spruce and pine—were made from the indigenous Hawaiian wood, a situation driven perhaps more by availabilty and cost rather than tonal considerations. The zenith of ukulele making in Hawaii was arguably reached by 1905, the year that Jose do Espirito Santo died. With the uke boom of the teens and twenties the mode of production moved from individuals hand-crafting instruments to factory operations both in Hawaii and on the mainland. As an enormously popular instrument, the uke was made incarnate in larger and larger forms from such seemingly disparate materials as wood, coconut shell, steel, tin, composition and plastic. With rare exception, the trend towards mass production lead to a cheapening of the instrument throughout the twentieth-century.
Consider the case of Harry E. Hall of Chicago, Illinois. When Hall filed a patent application in December 1925 for a mass-produced “sheet metal finger plate” for ukuleles, it was a milestone in the odyssey to low-cost and quick production. While Hall’s innovation eventually hit store shelves as a cheap brand called “Tru-Fret,” it had been his intention that the time and money saved by mass producing fingerboards would be lavished on better woods for the rest of the instrument: “Instruments of better tone quality than heretofore can be produced at a given price, not necessarily as a direct result of the tone qualities of the finger plate itself, as by reason of the great saving in price in the construction of the fingerboard, which makes it possible to put a better sound box in the instrument without increasing the total cost.” In practice the concept worked a little differently; inexpensive, mass produced fingerboards were attached to ukulele bodies made of inferior materials so as to further reduce costs and maximize profits. For instance, in the 1950s, ads for the Chicago manufacturer Harmony boasted that “Harmony creativeness and Harmony’s craftsmen teamed to produce this ingenious “Accurately Molded” polystyrene plastic fingerboard for moderately priced wood ukuleles. Offers fretting that is perfection itself. Mechanically exact - provides a freedom of technique hitherto unknown in low priced ukes.” Unfortunately the legacy left us by Harry E. Hall, at least with regard to ukulele construction, and notwithstanding his stated intentions, is this: vintage instruments constructed with molded, screw on fingerboards are the epitome of cheapness.
Ukuleles Go Plastic

ut what about the all-plastic ukuleles first manufactured in the 1950s? There were many brands, and several patents, all for injection-molded polystyrene instruments of varying quality. The Strad of plastic ukes was Mario Maccaferri’s Islander, made by Maccaferri’s Mastro Plastics Corp. in the Cremona of the West: Bronx, New York. Highly collectible today, the original plastic Maccaferri ukuleles were made of Dow Styron polystyrene and had Du Pont nylon strings supplied by the National Musical String Co. of New Brunswick, New Jersey. In March, 1950, according to a report in Newsweek Maccaferri was turning out 2,500 ukuleles a day—almost one every thirty seconds—with a backlog of 100,000 orders on hand. Plans for the rest of 1950 included projected sales of half-a-million ukuleles.
That same month an article in the Wall Street Journal credited a TV personality—and plastic—with popularizing the ukulele anew:
Arthur Godfrey, Styron Spark Ukulele Comeback
The ukulele business is coming back with a loud twang, thanks to Arthur Godfrey and Dow Chemical’s plastic, Styron. The ukulele was popular shortly after World War I when Hawaiian music first came in. After that it pretty well passed out of the picture.
The boom got under way last Summer, when Mr. Godfrey appeared on television with a uke. Seeing it apparently started up public demand again. The difficulty was to get an instrument cheap enough for popular sale. Mario Maccaferri, head of Mastro Plastics, who got his start making plastic reeds for wind instruments, worked with Dow engineers to design the all-plastic uke. The ukes have nylon strings and can be played under water if any one wants to try it.
Maccaferri had originally planned to invest $10,000 and turn out a five-dollar toy, but reconsidered. “I know how to make the best,” he reasoned. “Why shouldn’t I use all my experience and make a real ukulele?” Why, indeed. When he finally had a product he was satisfied with, Maccaferri had gambled $75,000 on the success of the Islander but “had a much better instrument” than he expected. The major expense was for the four large molding presses that turned out the eight major parts of the ukulele: body, neck, and head (in one molded unit); the soundboard; the fingerboard, with molded-in frets; the bridge, the soundboard ring; the head cover; the inside sound bar; and the nut. Maccaferri’s five U.S. patents covered everything separately from the nut, soundboard, and bridge to the fingerboard and the method of making it. Compared to the simple patents of George Finder and David Rosenheim, Maccaferri’s ukulele patents look like rocket science, and in a way they really are blueprints for making space-age ukes.

According to one early report, the Islander came “in all colors, and one model is flourescent.” The official line was “simulated rosewood, with the head cover and soundboard in ivory.” Over the years, countless variants were made (if there is an official tally of the different colors I have not seen it). Like Magnus and his plastic harmonica before him, Maccaferri reduced the number of parts needed to assemble an ukulele from about twenty-one for a wooden instrument, to eight for the Islander—excluding the strings and tuning pegs.
An article in Modern Plastics outlined the difficulties Maccaferri overcame with his design:
One of the largest problems encountered during the pre-production days of the Islander was the selection of a maerial formulation that would have all the properties and characteristics necessary for the particular application. Four months were spent on the choice of a material—one that would withstand the tension of the strings, one that would not distort or shrink during the life of the instrument, and one that would produce the correct pitch, resonance, and tonal quality. The final polystyrene formulation chosen combined the above requirements with resistance to the effects of dryness, moisture, heat, or cold.
Another production problem that had to be solved was the proper selection of an adhesive. The wrong adhesive would result in either shrinkage of the polystyrene or a marked deadening of sound in the completed instrument. According to the manufacturer, the selected adhesive further strengthens the polystyrene parts against the effects of dryness, moisture, heat, or cold.
For a finishing touch, Islanders were surface treated and waxed and packaged in re-usable polyethylene bags secured at the top with rubber bands! They retailed for $5.95 (later reduced to $3.95), and cost about $1.50 to make. Maccaferri said he made 25 cents on each instrument and the rest went to middlemen. The Islander line eventually featured several other products including an extended fingerboard model, a baritone ukulele, a child’s-sized Ukette, and a patented chording device called the Visual Chordmaster. Mastro Plastics Corp. continued making ukuleles well into the 1960s.
Applied music
n 1952, an American educator addressed the shortage of string players in schools by introducing experimental pre-string training classes for fourth-graders using ukuleles. William Mihalyi was inspired by a talk he heard at the first annual conference of ASTA (American String Teachers Association) in 1951 extolling the use of ukuleles to teach both vocal and instrumental music at the same time. Mihalyi wrote:
Upon my return home, I immediately contacted my supervisor, who agreed to try ukuleles for a pre-string training program. After considerable investigation we chose plastic ukuleles with nylon strings as the instrument to use in this experiment. The tone was fine, the construction showed attention to detail, and the possibility of “long life” seemed to be present.
The instrument Mihalyi chose was the Islander Ukette. And it opened his eyes. “Without a doubt there are those who will turn up their noses at the thought of using ukuleles in schools. It is not the accepted thing! I, myself, felt that way at one time. I had been taught to look down on certain instruments as being of a lower form than others. Such thoughts are now disappearing from my mind.” It’s not clear if the program ever progressed beyond the experimental stage (unlike the Canadian program introduced by Chalmers Doane), but results were apparently beyond expectations. Students interested in the violin made the change from ukette to fiddle easily. And Mihalyi noted another possible benefit from including the ukulele in a larger music curriculum: “Even in later life playing the ukulele could be a source of enjoyment in the home.” Was he predicting the Third Wave?

References from Modern Plastics, the Wall Street Journal, Newsweek, Music Educators Journal, and Fortune were used in this article.
Text and images © 2007 by John King

ne morning Edward Purvis awoke from a bad dream to find himself transformed into a diminutive, verminous insect. That’s the story, anyway: an article by Lorin Tarr Gill entitled “Portuguese Were First To Introduce Ukulele In Hawaii Says Miss Roberts” published in the magazine section of the Honolulu Advertiser on August 10, 1924. Forty-five years after the arrival of Madeiran cabinet makers who would craft and market the first ‘ukulele in Hawaii, the cultural memory of those remote times was rapidly fading. None of the principals involved in the story were alive in 1924, not the trio of cabinet makers cum luthiers, Dias, Santo and Nunes; not João Fernandes who claimed to be the first to play the machete in Hawai‘i in 1879 after disembarking from the Ravenscrag following a four-month voyage from Madeira; not Edward Purvis.
Charles H. Judd, the chamberlain and commissioner of crown lands, resigned “for certain improper conduct” on August 30, 1886, and Purvis resigned shortly after. Both were suspected of “feeding derogatory information about the government to the anti-Kalakaua newspaper, the Gazette.” Additionally, Purvis was probably the author or coauthor of two notorious burlesques on the Kalakaua monarchy: Grand Duke of Gynbergdrinkentstein and Gynberg Ballads. The caricature of Kalakaua shown here is attributed to Purvis and is from the Gynberg Ballads. The king is depicted holding a giant corkscrew—his left hand resting on an enormous gin bottle—and dressed in an Hawaiian postage stamp malo (bearing his likeness), spurs, garters, collar and cuffs. The illustration accompanies a parody entitled “The Order of the Bar.”
If you read that line without flinching (or even questioning the supposition) don’t feel too bad; it’s that old white magic, institutionalized racism. Mmm. Large-bodied slow-moving Hawaiians? Like the Kahanamoku brothers? Right. Here’s another take on the typical Hawaiian, from The Travel Diary of a Philospher by Count Hermann Keyserling:
The machete was exquisite. The turned ivory appointments, back and sides of Juniperus oxycedrus, spruce soundboard, rosewood bridge with finely wrought moustaches of miniature oak leaves and acorns, and the remains of a strap of colorful, twisted silk still attached to the peg head. It weighed in at fewer than seven ounces. The maker, Octaviano João Nunes da Paixão (1812-1874), is considered to be the most important among a handful of violeiros—stringed-instrument makers—known to have lived and worked in Madeira in the 19th century; a few of Nunes’ instruments survive in museums in Europe and in private collections in the U.S. However, the real treasure was not the machete, remarkable as it was, but the cache of old paper folded double on top of the instrument—the Estudos so casually described in Dr. Stradner’s email.
When I examined the manu-script the source of the spelling “Mabral” became clear. A casual perusal of the last name seemed to have a crossed-out letter “M” at the beginning, followed by “Cabràl.” I scanned the signature at 300dpi and looked at it in full resolution: the scratched out “M” was really an elaborate paraph or rubric made up from Cabràl’s initials, MJMC, the last of which ends in a flourish underscoring the other letters in the last name. The paraph is significant because it identifies the manuscript as an autograph, not merely the work of a copyist.
I was looking for the grave of Augusto Dias. It would have been about as old as the weathered marker in front of me, which I regarded with sober curiosity: a gray slab of crumbling, porous stone with pitted surfaces and ground off edges wearily upthrust through a rough-hewn granite base. Cratered by lichens and haired over with moss, the inscription was faint and without relief, as though melted, in the shadowless, muted light. I brushed the arc of letters—the name—with my fingertips, attempting to read it by touch, Braille-like, but the characters remained at large, elusive, anonymous.
The small congregation of Portuguese graves surrounding me lay laterally round the flank of Punchbowl Crater like a ruin, a few uneven rows of teetering, lonely memorials. Uphill, a multitude of impeccably cared for Buddhist monuments clustered together to honor issei ancestors; downhill, near the lava wall facing Pensacola Street, plots for the kama‘aina and privileged white oligarchy stretched out, royalists and republicans, patriots and revolutionaries, equal now in their final repose beneath the terraced, grass-covered hillock of Makiki Cemetery. Away to the south, the modern towers of bustling Honolulu rose against the sky; to the east, block upon block of tall hotels perched on the sandy apron of Waikiki Beach, squeezed between the rugged promontory of Diamond Head and the serene, blue Pacific.
To my right was the granite headstone of João Fernandes, a plumber from the island of Madeira who arrived in Honolulu in 1879. By his own account, João was the first person in Hawai‘i to play the Madeiran machete, the little four-string guitar we now call the ‘ukulele. Reminiscing in 1922, a year before his death, he recounted playing for Queen Lili‘uokalani, composer of the immortal Aloha O‘e, and for her brother Kalakaua, the Merry Monarch, Hawai‘i’s last king. “Good music that ukulele makes,” João mused. “Good for dance, for sing, for everything. I go out with August Dias and Joao Luiz Correa in the old days. We would go to the king’s bungalow. Lots of people came. Plenty kanakas. Much music, much hula, much kaukau, much drink. All time plenty drink. And King Kalakaua, he pay for all!” The old man suddenly became contemplative. “But now—now all pau [dead].”
João and his friend August—Augusto—Dias made the four-month voyage from Madeira to Honolulu together with more than four-hundred and twenty of their countrymen, including Correa and Dias’ common-law wife, Roselina, and their four daughters. Seeking to escape a cycle of poverty and famine brought on by the collapse of the Madeiran economy, the Madeirense migrated to Hawai‘i by the thousands beginning in 1878, lured by promises of easy money and a sub-tropical climate not unlike the one they were leaving behind. But once in Honolulu, representatives of the Hawaiian and Portuguese governments coerced Fernandes, Dias and the rest to sign up as contract laborers on the sugar plantations, hardy European stock to replace earlier immigrants from China against whom there was a great and malignant prejudice in Honolulu.
After several years working cane fields on the Big Island and Kaua‘i, Dias settled in Honolulu and resumed his former trade as a violeiro, or guitar maker. The first such craftsman to advertise his services in the Honolulu City Directory in 1884, Dias could count King Kalakaua among the influential patrons who frequented his shop at 11 King Street. In addition to encouraging the revival of traditional Hawaiian performing arts, particularly hula, Kalakaua popularized the ‘ukulele among his subjects, so much so that it quickly became the instrument of choice to accompany mele and the gentile hula ku‘i. Late in life, Dias’ eldest daughter, Christina—Auntie Tina—related that her father “enjoyed being part of the scene at Kalakaua’s court” and recalled that as a young woman she was often asked to translate for Augusto because he spoke very little English. This included conveying orders for custom-made guitars and ‘ukulele from the king, who spoke very little Portuguese.
With both knees planted and sinking in the hallowed ground, and my torso cantilevered out and over, I leaned in to get a closer look at the rough tablet. This was it, I thought. The end of the line. The last grave in the last row in the only Portuguese section of the cemetery. And the clock was ticking. I had a plane to catch. If only I had more time, there might be a break in the overcast. I reached out once more. The surface of the stone was sharp and wet against my fingers and wept where I touched it, sending angular rills of tear-like droplets down the rock face. And then it happened. The clouds relented, admitting effulgent streams of sunlight that swirled across the hillside, casting crisp, black shadows. The fuzzy, run-together letters of the inscription drew up in tight focus. It was in Portuguese:
emember the “free-roaming, vaporous, full-torso apparition” at the New York Public Library in the opening sequence of the 1984 film Ghostbusters? It spewed cards from the card catalog, blew books from the stacks and scared the socks off the prim librarian. Only in the movies, right? Well, think again. Ghosts do exist. Particularly in libraries. I’ve seen one.
He stares out at me from the dust jacket collage of George Kanahele’s Hawaiian Music and Musicians, a hand-tinted taropatch player perched on the left shoulder of King Kalakaua and flanked by Tandy Mackenzie and the Brothers Cazimero. It’s Ernest Kaai—Hawaii’s Music Man—the preeminent ‘ukulele player of his generation. I flip to the entry on Kaai; page 193. There he is again, same picture but cropped to just a head shot with the caption “Ernest K. Kaai. From his book The Ukulele.”
The three pages of text on Kaai in HMM probably comprise the most extensive biography of the man ever written, appropriately brief but full of wonderful facts: “…mandolin virtuoso, vocalist, publisher, composer/arranger, teacher, bandleader, impresario. Performed at Yukon Exposition in Seattle (1906); toured Australia (1911); recorded for Columbia in Honolulu (1911); featured at San Francisco and San Diego expositions (1915-1916); published ‘ukulele instruction manual (1916).”
Hey, I think. I have a copy of Kaai’s 1916 method in my stack of ‘ukulele primers. It’s a beauty, too: full-folio with chocolate-brown paper wrappers and a marvelous half-tone frontispiece portrait of Kaai. But something’s not right. The title of my Kaai 1916 is The Ukulele and How It’s Played, not The Ukulele: A Hawaiian Guitar and the picture isn’t the one referenced by Kanahele. And it was published by The Hawaiian News Company, not Wall, Nichols. And I have a bunch of ‘ukulele methods published in California in the early 1910s. Way before 1916. What’s up with that? And would Kaai really have published two different methods with two different Honolulu publishers in the same year?
I sneak away during a family vacation to spend a couple of precious hours doing research. Through the internet, via telnet, I learn there is a copy of a Kaai method at the Hamilton Library with the same title and publisher as the one in Kanahele—The Ukulele: A Hawaiian Guitar—but apparently with a copyright date of 1910! I’m here to scope it out. Most of the books in the Hawaiian Collection have to be paged and the Kaai is no exception. I surrender my driver’s license as collateral, fill out the page form and turn it in at the desk.
hey say you always find the things you’ve lost in the last place you look. The HMCS Library wasn’t simply the last place I looked, it was the last place to look. I visited the library in 2004, compared their Kaai 1906 to a copy of the Revised 1910 and noted the differences—not many: re-engraved, some corrections, of course a different picture of Kaai—the one in Hawaiian Music and Musicians. The head librarian, Marilyn Reppun, was kind enough to make a photocopy for my records which I picked up the next day.
Recently I acquired an original of the Kaai 1906, from a Goodwill store in Oregon. Black paper wrappers printed with gold ink, a small octavo-size, just right to slip into an ‘ukulele case. And do you know what’s funny? It has one less piece than the copy at the HMCS Library. Nothing is missing from either one; there are just two states. I believe mine is the earlier: on page 21 (out of 39 pp.), Kaai references ‘preludes’ when there is only one prelude to be found. In the HMCS Library copy, a second prelude is printed on page 40, the verso of page 39, which is blank in my copy. It was apparently left out of the first printing and inserted out of sequence in the next. What’s wonderful about the copy I have is that it’s filled with annotations and corrections by Kaai himself. The original owner obviously took lessons from “Hawaii’s Music Man.”
I first came across this beautiful image in Nathaniel Emerson’s pioneering work, Unwritten Literature of Hawaii: The Sacred Songs of the Hula (Washington, D.C., 1909). Captioned ‘Hawaiian Musician Playing on the Uku-lele’ and printed with the permission of the artist, Hubert Vos (1855-1935), I was dumbfounded that this masterful painting was virtually unknown in the lexicon of ‘ukulele iconography. I wondered what had become of the original. Nearly as surprising was my next encounter with Vos’ ‘ukulele player. While perusing a copy of The Oxford English Dictionary, Vol. XVIII (Oxford, 1989) at the Poynter Library, USF St Petersburg, I stumbled upon this citation:
It was shortly after I released my Bach CD in 2001 that I learned Vos’ painting (titled Kolomona: The Hawaiian Troubador) was part of the permanent collection of the Honolulu Academy of Art, a gift of Henry B. Clark, Jr. in 1994. A year later the Art Academy produced a CD entitled The Art of Solo ‘Ukulele (I’m grateful to Byron Yasui for my copy) which included performances by Byron, Benny Chong, Gordon Mark, and Jake Shimabukuro. Not surprisingly, the cover art featured a full-color reproduction of the Vos painting.
Since then, Kolomona has shown up a few more times. The Hawaiian Historical Society used an image of the 1900 Century Magazine litho for the cover of The Hawaiian Journal of History, Vol. 37, 2003 which featured an article by Jim Tranquada and me (‘A New History of the Origins and Development of the ‘Ukulele, 1838-1915’); Spirit of Aloha (November-December 2005), the in-flight magazine of Aloha Airlines, used the same image as a full-page illustration to accompany an article I wrote entitled ‘How I Learned to Play the Ukulele.’ Recently, at Byron’s suggestion, I provided Malamalama, the alumni magazine of the University of Hawai‘i, with several illustrations, including Kolomona. It accompanied an article by UH alum George Furukawa called ‘An ‘Ukulele Comeback’ (Vol. 32, No. 1, January 2007).