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Transcript Notes Here!
Every great mandolin has a story.
Sometimes that story begins in the hands of a legendary player. Other times it begins quietly on the workbench of a master craftsman whose job is to bring an instrument back to life—or to create one from scratch.
For Episode 313 of the Mandolins and Beer Podcast, I sat down with acclaimed luthier Hugh Hansen, one of Nashville’s most respected repair specialists and mandolin builders.
If you’ve spent much time around high-end mandolins, chances are you’ve already encountered Hugh’s work. From restoring vintage Gibson F-5s to building his own sought-after instruments, he’s earned a reputation for meticulous craftsmanship and thoughtful attention to tone.
During our conversation, Hugh shares his path from growing up on a Nebraska farm to attending the renowned instrument repair program in Red Wing, Minnesota, working alongside George Gruhn in Nashville, collaborating with master builder Stephen Gilchrist, and eventually establishing his own respected shop.
What makes this conversation especially fascinating is that it goes well beyond repair work. Hugh explains how great mandolins are designed, why wood selection matters so much, how humidity affects every acoustic instrument, and why patience and observation remain some of a luthier’s greatest tools.
Whether you’re a professional player, a collector, or simply someone who wants to better understand the instrument in your hands, this episode offers a rare glimpse into the mind of someone who has dedicated his life to making mandolins perform at their absolute best.
In This Episode
You’ll learn:
- How Hugh Hansen became a professional luthier
- What he learned working at Gruhn Guitars
- His relationship with master builder Stephen Gilchrist
- How tonewoods influence sound
- Why humidity is one of the biggest threats to acoustic instruments
- What makes a great vintage mandolin
- Tips for caring for your instrument
- The philosophy behind building exceptional mandolins
Why Hugh Hansen Has Earned the Trust of Top Players
One theme runs throughout this interview: trust.
Repairing an instrument worth tens—or even hundreds—of thousands of dollars requires more than technical skill. It requires judgment, patience, and an understanding of why the instrument became special in the first place.
Hugh discusses working on some of the finest vintage Gibson mandolins in existence while developing a philosophy focused on preserving rather than reinventing great instruments.
Learning From the Best
One of the highlights of the conversation is Hugh’s description of working alongside George Gruhn.
Rather than simply learning repair techniques, Hugh explains how seeing countless vintage instruments helped him understand what truly separates exceptional mandolins from ordinary ones.
Sometimes the lesson wasn’t theoretical—it was simply putting another instrument into his hands and saying, “Play this one.”
Those experiences shaped the standards he still uses today.
Building Mandolins Is More Than Woodworking
Many people assume building a mandolin is simply woodworking.
Hugh explains why that’s only part of the story.
Choosing the right spruce and maple, understanding how finishes affect vibration, carving plates, voicing an instrument, and balancing strength with responsiveness all contribute to an instrument’s personality.
Perhaps the biggest takeaway is his insistence that great tone starts long before the first cut is made—with exceptional wood.
Humidity: The Biggest Mistake Most Players Make
If every mandolin owner reads one section of this interview, it should probably be this one.
Hugh offers practical advice on:
- maintaining stable humidity
- avoiding excessive moisture
- using hygrometers
- choosing humidification systems
- preventing cracks and loose braces
It’s some of the clearest advice I’ve heard from an experienced repair professional.
Favorite Quotes
“If you want good wood, you have to go get it.”
“The instrument is much happier being stable.”
“You can make a lot of mistakes, but exceptional wood forgives a lot.”
“Sometimes the answer was so different than what I expected that I thought Steve was messing with me.”
Gear & Topics Mentioned
Builders
- Hugh Hansen
- Stephen Gilchrist
- George Gruhn
Tonewoods
- Red Spruce
- Sugar Maple
Finish
- Spirit Varnish
- Shellac
Humidity
- Hygrometers
- Humidipaks
- Sponge humidifiers
Vintage Instruments
- Gibson F-5
- Lloyd Loar era mandolins
Five Takeaways
Great repair work preserves history.
Rather than changing instruments, Hugh focuses on restoring them to their original potential.
Great builders never stop learning.
Even after hundreds of instruments, Hugh says every build teaches him something new.
Wood matters more than many people realize.
Exceptional tone begins with exceptional materials.
Humidity control is essential.
Keeping your instrument stable is more important than chasing the perfect humidity number.
Vintage instruments still have lessons to teach.
Studying the best instruments ever built continues to influence today’s finest builders.
FAQ
Who is Hugh Hansen?
Hugh Hansen is a Nashville-based mandolin builder and repair specialist known for restoring vintage instruments and building handcrafted mandolins.
Does Hugh Hansen build mandolins?
Yes. Along with his repair work, Hugh builds handcrafted mandolins that are highly regarded by professional musicians.
What finish does Hugh Hansen prefer?
He discusses his preference for traditional spirit varnish because of its flexibility and tonal characteristics.
What humidity should a mandolin be kept at?
Hugh recommends maintaining a stable environment around 40–50% relative humidity, while emphasizing that stability is more important than constant swings.
What woods make the best bluegrass mandolin?
Hugh explains why high-quality red spruce paired with hard sugar maple has become the classic recipe for projection and clarity in bluegrass mandolins.
Editor’s Note
Every episode of the Mandolins and Beer Podcast explores the people, instruments, and craftsmanship that shape the world of mandolin music. Whether the guest is a performer, builder, teacher, or historian, these conversations are designed to help players deepen both their appreciation of the instrument and their own musical journey.