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Old March 2nd, 2010, 12:36 PM   #1 (permalink)
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2010 TDPRI $210 Challenge-????Caster

Bought this piece of 8/4 hard maple yesterday.

......

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Old March 2nd, 2010, 12:58 PM   #2 (permalink)
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Can't wait to see what you come up with.
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Old March 2nd, 2010, 01:00 PM   #3 (permalink)
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And the plot thickens! I don't see myself doing anything but hitting refresh on my browser for the next two months. I'm excited you've joined the fray.
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Old March 2nd, 2010, 01:59 PM   #4 (permalink)
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should be a good one
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Old March 2nd, 2010, 02:09 PM   #5 (permalink)
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Maybe I should just beg out now...
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Old March 2nd, 2010, 02:18 PM   #6 (permalink)
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Go Jack
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Old March 2nd, 2010, 02:33 PM   #7 (permalink)
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you do good work....and are the reason I completely decided to change colors on my USACG BUILD.....this will be epic, I knows it already
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Old March 2nd, 2010, 02:44 PM   #8 (permalink)
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Don't expect too much guys. Still searching for an idea.
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Old March 2nd, 2010, 03:02 PM   #9 (permalink)
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build a telecaster with it.
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Old March 2nd, 2010, 04:26 PM   #10 (permalink)
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Yeah! Fendorst has the right idea!
Serious though Jack, I'm glad you joined! This should become an entertaining and educational thread to say the least.
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Old March 2nd, 2010, 07:49 PM   #11 (permalink)
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Quote:
Originally Posted by Jack Wells View Post
Don't expect too much guys. Still searching for an idea.

My light bulb lit bright today, decide on some details. Changed the mantelcaster to the mental caster, just could not edit the OP / Thread title... ;)
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Old March 2nd, 2010, 10:03 PM   #12 (permalink)
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Quote:
Originally Posted by Jack Wells View Post
Don't expect too much guys. Still searching for an idea.
Haha! You're reputation precedes you and now you have to live up to it!
Even if you built a run-of-the-mill tele (which you never do), I'd still be interested because you write some of the most informative, interesting threads.
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Old March 5th, 2010, 08:51 PM   #13 (permalink)
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Determining Body Wood Cost.

I purchased an 8 ft piece of 8/4 hard maple ~ 8 in. wide. Actually it was a little less than 8 in. wide and less than 2 in. thick but they write it up as a 2x8. In theory I could get three bodies from this board. However there is checking on each end of the board. I've chosen to allow 3 in. waste at this end.

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Here are the two pieces that will make up the body. By joining the common edge in the center, you get a less visible joint line.

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Cost Calculation:

2x8x(16+19)=560 cu. in.

560/144=3.89 board feet.

3.89 x $4.36 = $16.95 + 5.94% tax = $17.96
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Old March 16th, 2010, 05:39 PM   #14 (permalink)
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My career hasn't allowed me to do any work on this project until today. I start by taking off some of the excess width from the boards which will make up the body blank.

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After running them through the jointer we're ready for the glue-up.

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Clamps in place.

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Glue squeeze-out wiped away.

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Since this wood measures just a hair over 1 3/4 in., I've decided not to run it through the thickness planer.

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Instead I'll use the belt sander and orbital sander to smooth it out.

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I attach the template to the blank with two screws ......... one in the bridge area and the other between the neck pocket area and neck pickup cavity area. Then I trace the shape and cavity outlines.

......
......

A trip to the bandsaw................

......

.... yields this.

......
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Old March 16th, 2010, 05:55 PM   #15 (permalink)
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Looking good so far.
Is this going to be a standard tele, or have you got something more exciting in mind?
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Old March 16th, 2010, 07:05 PM   #16 (permalink)
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I always rout my body shapes using 'downhill routing' as depicted in the following diagram making several shallow passes.

......

This is as far as I could get with the template.

......

I had dropped the bit into the collet as far as it would go. After removing the template there still wasn't enough bit to finish the job so I raised it in the collet about a half inch. There's still plenty of shaft in the collet.

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As you can see, now the bit can be raised high enough to finish the job.

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Body shape routing completed. The remainder was done in three passes. Some in earlier threads have spoken in a negative manner about my 'downhill routing' technique and some have actually said it caused tearout. I think they may be a little unclear on the concept or are inexperienced in the use of routers. Here we have a 1 3/4 in. body made from hard maple with no tearout.

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Quote:
Is this going to be a standard tele, or have you got something more exciting in mind?
Hmmmm............. Let's see........... you can buy a standard Tele. Why build something you can buy? It won't be a typical Tele but don't expect something too exiting either.
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Old March 16th, 2010, 08:44 PM   #17 (permalink)
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Predrilling cavities with a Forstner bit.

......

Here's a little trick for getting your control cavity depth correct. Lay a piece of 1/4 in. material alongside the body and adjust the bit depth until it touches it.

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Cavities done. Next up ............ neck pocket.

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My neck pocket template attaches with the same screw holes as the body template so indexing is automatic. Since this template is only 1/4 in. MDF, it's good to have a pattern bit that's only 1/2 in. long.

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First router pass after predrilling the neck pocket.

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Neck pocket routing complete. It measures 0.630 in. deep ....... close enough.

......

Enough for today. Now it's time for Lost.
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Last edited by Jack Wells; March 16th, 2010 at 09:26 PM.
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Old March 16th, 2010, 09:49 PM   #18 (permalink)
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Lookin good!
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Old March 17th, 2010, 02:26 AM   #19 (permalink)
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As my Old Man would've said: If I didn't know better I'd say it looks just like a guitar! Nice going Mr. Jack!
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Old March 17th, 2010, 06:51 PM   #20 (permalink)
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Here's my set-up for drilling the jack hole. One could probably make a simple jig for doing this job. In fact, I seem to remember that Ed Hawley designed just such a jig.

......

Well, this step in complete. Here's the outside...........

......

...... and here's the inside.

......
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