RogerC's 2012 Challenge Build Thread - COMPLETED

[Matt Haskins]

I say go for it! It can't be any heavier than this 1970s Les Paul I had when I was a teenager.

[RogerC]

Thanks guys. I'll be starting my form construction tonight, but I won't be able to complete it because I have to get my bridge and pup in first to make sure my measurments are accurate. This will be difficult for a number of reasons, not the least of which is that math is not my strong suit (English degree)

I mean, I can count and all, but...

[dilbone]

looks like you're going to need a bigger strap.... Good Luck, can't wait to see this one unfold...errr...form up...

[oigun]

Who needs intonation anyway?? Slab the bridge on, secure it with drywall screws and forget about it... :D
Calculation is for pussie's.

[RogerC]

Originally Posted by dilbone

looks like you're going to need a bigger strap.... Good Luck, can't wait to see this one unfold...errr...form up...

I've got an idea to reduce the weight. We'll see if it works

Originally Posted by oigun

Who needs intonation anyway?? Slab the bridge on, secure it with drywall screws and forget about it... :D
Calculation is for pussie's.

I was thinking about just putting 5 frets on there. I never play above that anyway

[Allthesound]

That idea sounds really cool Roger! Cant wait to see how you achieve a manageable weight.

[GunsOfBrixton]

Looking forward to this one Roger. Thinking of adding tint to the concrete as the finish? Or embedding pieces of glass, metal, tile etc...?

Good luck!

Robert

[RogerC]

No, Robert. It's just going to be raw cement. The plan is to use construction materials- cement, wood, bolts, screws, etc...

[guitarbuilder]

I had thought of plaster and cement too. We have a ceramics shop down the road and I even considered pouring a slipcaster......LOL...

Decided the mold wasn't worth the effort for me....this should be fun to watch. Good luck with it all.

[tvvoodoo]

Going to be interesting, fo' sho' - cheering you on Roger

[RogerC]

Thanks man. I appreciate that. With all the heavy hitters here, I'm waaay outclassed

[nosmo]

I'm thinkin' that will indeed be a heavy hitter. You must play some rough places.
Good luck - I'm looking forward to seeing it.

[RogerC]

The group shot. We have tempered masonite, 2" extruded styrofoam, mahogany, walnut, misc dowel rods, and oh yeah a 94lb bag of portland cement


Oh, and my secret weapon for mixing up a light weight batch

The theory is that the lighter perlite will lower the density of the mix, thereby causing it be lighter. It sounds good anyway

The styrofoam will be my outside form. First thing I had to do was get it to a manageable size



Next, I marked its center line, laid out my template and traced




I then had to mark out my neck pocket area

You'll notice that it's upside down. I debated on this for a while about which way to make my form-- right side up or upside down. There were advantages and drawbacks to both, but I finally decided that there were more advantages to pouring the mold upside down.

Next I had to cut out the form. Start with a little hole...


And move to the scroll saw


Let me tell you, styrofoam is actually too easy to cut with a scroll saw. It didn't even matter which way my blade was facing. I was cutting sideways even . All in all, after a little sanding with a worn out piece of 320, it turned out very nice


I have it sitting on my piece of masonite which will act as the base. The idea is that the smooth surface will make a smooth face on the front of the guitar as it dries. It will also act as an anchor for the internal parts of the mold.

Next up, neck and fretboard stock...

[RogerC]

Here's my mahogany neck stock with my template on to mark for rough length


Next was trimming to rough length. don't have to be too precise at this point


Since the neck stock was too narrow, I had to glue on an ear. First I had to prep the top edge


Since my jointer isn't that great, I finished up the jointing surface on my plate glass/sandpaper surfacer


I then cut off a section to make the ear


And busted out the titebond and clamps in preparation


If you look closely, it kinda looks like a dragon. RAWR

Then I turned my attention to a piece of scrap walnut for a fretboard. I picked out the thickest one and started to trim it down to a manageable shape


The only thing I'm a little worried about is the small knot area. It looks like it's going to fall around the 16th fret or so, and mainly be in line with a fret slot. I'll just have to see how it works out. I can always cut a piece from my larger stash if I need to.

Not bad progress for the first evening. I'll be focusing on the neck for the next week or so. I'll have to wait until my taxes come back before I can afford to buy any hardware.

[collectiveoasis]

Great progress, I'm curious to see how this turns out, it's a cool idea.

[RogerC]

Originally Posted by collectiveoasis

...I'm curious to see how this turns out...

You and me both

[nosmo]

"And he's out of the gates runnin' " or so someone once said to me.

This is going to be really interesting.

[devo_stevo]

cool. cant wait to see how this one goes.

[Muzikp]

I still can't believe this is happening. I just can't imagine how you are going to pull it off but I already can't wait for the next update.

[Joe Sailor]

I love the smell of concrete in the morning! Bold choice. Chicken wire mesh? I polished my concrete floor and sprayed it with stain, surprisingly smooth. Holds up well.