2010 TDPRI $210 Challenge - Justacaster

[Guitarnut]

Well, I joined the TDPRI last year as the challenge was wraping up. I'm thrilled to see this come around again. I'm in!!! The name Just A Caster, means I'm going for fit and finish. No fancy top or binding. Just classic lines and pristine finish...that's my goal anyway.

It will be made from Alder with a maple neck, rosewood fretboard...may change this so there's plenty of maple pictured for a neck and fretboard. Most of the hardware will come from an eBay purchase. I bought the whole lot pictured (bridges, pots, switches, tuners, ferrules) for $100 so I'll have to figure out what costs what after I decide what I'm using.

Glad to be a part of this year's challenge!



Peace,
Mark

[jrich99]

Can't wait to see it. Nice lot of parts for 100 bucks, too.

[68thinline]

Glad to see you getting in on this year's challenge. That looks like quite the hardware stash - and a nice piece of maple too!

[Guitarnut]

I started on the build tonight by getting that pile of wood into shapes that make guitar building easier.

I took a good look at the alder I had in the first pic and discovered an issue...a large check right in the middle of one of the pieces. After a brief %$*&*%$% moment, I came up with an idea. This is going to be an opaque finish so I can cut the .50" out of the center and make a 3-piece blank. No problem.



I figured out I could get a 3.25" cut on either side of the crack, so I set my bandsaw and



This will make a nice roomy blank side to side, but I have precious little room front to back. At the bottom of the pic you can see the strip I removed on the bandsaw.

[Guitarnut]

While I had the bandsaw set up, I decided to cut the neck blank as well.

My saw has been modified with a flatter table so I can resaw up to 6.75". After changing to a resaw blade, I set up the fence for a cut of just over 1". This will leave me plenty of room for planing as both sides of this billet are rough from previous bandsaw passes during other builds.



I'm always amazed at the accuracy of my little resaw rig. I hear guys complain all the time about blade drift on their $500 bandsaws...no such issues here...straight and true all the way down the pass.



My truss rod jig is set up for a 4" blank, so I need to rip this down. 4" is just before the mineral streak...that's lucky.



I was going to rip the entire length but then I realized I could flip the template and offset the mineral streak so it cuts away during profiling of the neck. This let me save a 15" cutoff at full width before ripping.



There it is. Ready to go.

[Guitarnut]

That pile I started with looks much better now.



On to the jointer. This thing saves huge time in making joints! I always check the fence before each job because of the way the Shopsmith tools are put on and taken off...it gets moved around quite a bit.

Before I started, I use a straight edge to find the flattest edge and then mark the other with an "X"...this means cutting away less width to get a clean joint.



All jointed and ready to glue up. I like using a plastic squeegee to spread the glue. It's fast and cleaner than my fingers.



All clamped up. It'll be ready for planing tomorrow. I'll plane the neck blank too before setting it up for truss rod routing. The planer won't square 2 edges to a corner but it will create parallel surfaces opposite eachother. In the past, I took for granted that the sides were parallel on a few neck blanks and paid the price after gluing up the fretboard...alot more work truing the neck when it's too late to run it thru the planer.



Peace,
Mark

[Guitarnut]

Originally Posted by jrich99

Can't wait to see it. Nice lot of parts for 100 bucks, too.

Thanks! They're all used. I thought at the time $100 bucks was high, but there are plenty of usable parts in there.

Peace,
Mark

[Guitarnut]

Originally Posted by 68thinline

Glad to see you getting in on this year's challenge. That looks like quite the hardware stash - and a nice piece of maple too!

Thanks 68! The maple is the same billet I cut my Maple Thinline from...top, back and neck. After the neck blank, I have enough to resaw for 2 more thin bookmatched tops. EDIT: Or, one thick carved top.

Peace,
Mark

[edd677]

Lookin good! Thats a nice little resaw setup you made and good results as well.

Ed

[68thinline]

You guys with the bandsaws always make me envious. I simply have to get one soon.

[Guitarnut]

Originally Posted by 68thinline

You guys with the bandsaws always make me envious. I simply have to get one soon.

I got lucky and bought my Shopsmith with the 4" jointer and bandsaw for $600 on Craig's List. Only had to drive 20 mins to pick it up, too. Always some good tool deals on there.

Peace,
Mark

[paulskirocks]

Originally Posted by 68thinline

You guys with the bandsaws always make me envious. I simply have to get one soon.

That's on my list this month...

[Guitarnut]

I took the body blank out of the clamps last night. You might be wondering why I glued up the outer pieces with equal amounts to eaither side instead of lining up one end. I did this to help control planer snipe. The middle piece is long enough for the body, so the extra legnth will keep the planer rollers steady while the middle enters and exits.

Here's some progress shots.

1. Out of the clamps.
2. I took .50" off each edge to get it down to 13"...the width of the planer
3. Planed down to a touch over 1.75"
4. Rough cut on the bandsaw.



1. Set up for profiling. I start with a pattern bit and make 3 passes.
2. I remove the template, flip the body and switch to a flush trim bit.
3. Profiling finished.
4. Before I sand any edges, I route the neck pocket.



All of the routing completed. I just need to locate the bridge and drill string thru/ferrule holes. And bore for the output jack.



I planed the neck blank too. It's just over .750". The rosewood fretboard is about .325", so after truing and radiusing, it will be within a few thousandths of 1".



Peace,
Mark

[68thinline]

Originally Posted by Guitarnut

I toll the body blank out of the clamps last night. You might be wondering why I glued up the outer pieces with equal amounts to eaither side instead of lining up one end. I did this to help control planer snipe. The middle piece is long enough for the body, so the extra legnth will keep the planer rollers steady while the middle enters and exits.

Good thinking.

The figure on that maple is real nice. It should make one pretty neck.

[wisdom 86]

Good looking hunk of maple. Major score on the lot for $100. Darn I need a bandsaw.

[Guitarnut]

I got started on the neck last night.

My simple jig for truss rod routing. Even though this one has worked well, I need a better setup. The accuracy is fine, but setuip is somewhat slow and not fool proof...follow along and you'll see.




Routing the channel was simple enough...next pic.



The rod lays in nicely...anyone see the problem yet?

Turns out, the jig is set up for a 4.5" blank not 4". So after routing the channel and tracing the neck profile...I was headed to the bandsaw and realized, I just made a left hand neck...not the plan.



This blank is too nice to waste and I don't want a lefty neck (no offense, it's just not for me) so, this baby's gettin' a "faux" skunk stripe.

I shaped a piece of walnut and glued it in. Let it set up and planed it flat with the blank. Not a lot of work but had I been paying attention...

[Guitarnut]

With that taken care of, and the channel routed on the correct side, I moved on to profiling. I started with a pattern bit and made a few passes.



Then I flipped the neck and switched to a flush trim bit like I did on the body.



I drilled the access hole for the adjustment nut and layed in the truss rod. Here are both sides. Came out okay...the skunk stripe is a bit long, but I don't see it affecting anything structurally.



Peace,
Mark

[edd677]

Coming along great, the body and neck both look fantastic.

Ed

[bluebilly]

HA! I did that same thing (made a LH neck) I called it a reverse headstock.... Yeah I wanted to do that.....

[Guitarnut]

Just a quick update. I've been off this build for a week or so finishing up 3 others. I'm scheduled to do studio photography this evening and put the other 3 builds to bed.

I'll be back on the Challenge strong this weekend. Some great builds going here...I may have to re-think my simple, classic approach.

Look for updates Sat and Sun.

Peace,
Mark