*Making A Reasonable Facsimile Guitar*

Several months ago I ordered an SX guitar from Rondo Music. When it arrived, I was very disappointed to find that Rondo Kurt had the bright idea to tell the Chinese factory to start staggering the string through holes. He claims it was due to customer demand ............ yeah right.

I ordered this guitar thinking it would be a good starting point in building a facsimile guitar. However, the staggered string though holes just wouldn't do. Here I'm attempting to correct Rondo Kurt's bright idea.

I purchased a 3/8 in. plug cutter. Here I'm cutting plugs in scrap and testing the plugs in some holes. As it turns out, the plugs are a little small to fill a 3/8 in. hole. I found that a 23/64 bit drilled the right size hole for the plugs.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06140.jpg

I drill out the existing 5/16 in. staggered holes on the back with the 23/64 in. bit.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06141.jpg

I drill my six plugs from the front of the guitar......

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06142.jpg

..... and glue them into the back aligning the grain.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06148.jpg

The holes on the front are drilled out using a bit sized to a dowel I had at hand.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06143.jpg

Dowels are glued in .......

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06144.jpg

.....sawed off with a hacksaw blade with the teeth hammered flat......

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06145.jpg

....and sanded flush.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06146.jpg

Nice Jack, thanks for sharing some more of your adventures with us. Are you gonna let us know what it's gonna be a replica of or keep us waiting?

It should be clear pretty soon what it is a facsimile of. Some can probably tell already by the color of the body.

Here's the SX neck. Another of Rondo Kurt's bright ideas.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC05739.jpg

I've done a little modification to it.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC05745.jpg
......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC05748.jpg
......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC05749.jpg
......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC05752.jpg

Also, the neck's a little too orange for what I have in mind.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC05757.jpg

....... a little too orange......


I never thought I'd see the day... :shock:

Really nice job on the headstock!

That is some wild work on that headstock...nice match. I can't wait to see finished product.

Muddy Waters tribute tele clone?

We know it's a Tele of some sort! Can't wait to see it.

I never thought I'd see the day... :shock:

+ some huge number

Muddy Waters tribute tele clone?

Nope. Couple of hints: Body is a sunburst and the neck isn't too orange.

Maybe I missed that, but what did you use to de-orangise the neck?

Paint stripper.

Andy Summers tele? It's sunburst and a lighter maple neck, so that's my best guess.

Good job PHawley ! Sorry there's not a prize.

I can't wait to see how you blend those plugs, Jack. You gonna melt the finish?

Schweeeeet.

http://www.andysummers.com/images/0150066800v4_xl.jpg

Hope to make it look like that ......... but we'll see. I've got a lot of pictures.

know the feeling... I had to do the same on this lefty body.. that the user plays strung righty.. so the staggers were all the wrong way to get the bass intoned....
I just made plugs as deep as the ferrules were... and some plain dowel wood.. pva glued them in.. too easy..:cool:

I just angled the string holes under the bridge to let the strings lead in ok off the new saddle positions...... and matching the finish, mhea.. who cares?...

there's a P90 in it now... the tele neck pu worked ok with the gibbo HB.. I had a spare p90 to try.. it goes good too...:smile:

Scaled a picture of the back of the AS Telcaster to actual size and made a template then a rear cover. The plugs for the staggered holes didn't turn out that great but they're better than dowel plugs would have been. I'll be using a Mexican standard bridge. The SX string through holes are offset quite a bit from the Fender location so the complete plugs show. Originally, I was hoping the new string through holes would partially cover the plugs.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06156.jpg

Someone in the forum was kind enough to post this picture.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/OnboardElectronicsA.jpg

I made a template for the cavities for the battery and onboard electronics. Didn't try to get it exact. Shifted things a little to ensure the cover covered the cavities

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06151.jpg

Screwed the template to the body using the cover screw holes.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06152.jpg

First routing of the rear cavities. Don't know how deep to rout the electronics cavity. If needed I can rout it deeper when I get the circuit board. Will rout parts of that cavity 1 1/2 in. deep for the extra pot and switch when I determine their position.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06155.jpg

Suggestion for your Christmas wish list: Ridgid Laminate Trimmer This thing is great and I feel it has features making it superior to the Bosch.

I mark the locations of the switch and pot with an awl.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06158.jpg

Then I drill 1/8 in. pilot holes.

http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06159.jpg

I see that I don't need to rout for the switch and pot but can do it with a Forstner bit.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06161.jpg

Here's the result. The switch will probably also need a 3/8 in. hole but since I don't have it in hand, I'll wait to drill that hole.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06162.jpg

cool. hey jack i have a question what does the extra switch and knob do?
also are you going to add binding or does it already have it, i can't tell from the pics

To answer your questions about the extra switches and pot, I'll refer you to the following review rather than my just parroting what I read there.

http://www.tdpri.com/forum/2142766-post1.html

I can answer the question about the binding. The SX came with binding. It's really a nicely finished guitar. Too bad that Rondo Kurt had to redisign the bridge.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06164.jpg

subscribing... I always like the things Jack Wells comes up with.

To answer your questions about the extra switches and pot, I'll refer you to the following review rather than my just parroting what I read there.

http://www.tdpri.com/forum/2142766-post1.html

I can answer the question about the binding. The SX came with binding. It's really a nicely finished guitar. Too bad that Rondo Kurt had to redisign the bridge.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06164.jpg

thanks for the link, this will be fun to watch:grin:

OH MY GOSH! Andy summers' tele has to be my favorite tele EVER! please keep us as updated as possible!

Looks like the SX neck plate hole pattern is different from Fenders. I don't want to use the SX plate with the logo so it looks like I'll be plugging and redrilling holes in both the neck and neck pocket.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06165.jpg

Here's the neck plate I'll be using . I've dulled the finish with sandpaper.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06166.jpg

I think I'll try using Duplicolor MetalCast to get it close to this color. I can't see myself spending $135 for that Armadillo bridge.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/2551053350053652852asYwEY_fs.jpg

I didn't have the right size dowel to plug the holes in the SX neck pocket so I resized a larger one with a rasp and the drill press.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06171.jpg

Glued them in and sawed them flush with a hacksaw blade with the teeth hammered flat.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06172.jpg
......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06173.jpg

I've ordered mini-switches fom Guitar Parts Resource. According to their website, the switch fits in a 1/4 in. hole so I went ahead and drilled the holes for them. They sure seem small.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06174.jpg
......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06175.jpg

Made the pickguard. Removed the gloss by wet-sanding with 600 paper.

Here's a little tip. The string through holes in the bridge plate are larger than 1/8 in. so 1/8 in. drill bits or dowels placed in the outside holes allow the bridge to move around. I cut a slightly oversize dowel and sharpened the ends in a pencil sharpener. Now the bridge is solidly locked in place for marking the bridge mounting holes. I'm off to the store to get a self-centering punch.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06176.jpg

This SX sunburst is very red in the center. This presents a problem I hadn't foreseen.

The Andy Summers Telecaster has a heel adjust neck. Since I'm using a headstock adjust neck, I've made a plug for the headstock. I'll use a small dab of E-6000 to hold it in place so it can be easily romoved.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06177.jpg
......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06178.jpg

A good day today. Received three packages .......... big sheet of white plastic, a pickup from GFS (these two items are for the mystery project) and pots and mini-switches from Guitar Parts Resources. They were right, the switches do fit in a 1/4 in. hole.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06192.jpg

Went to a very well stocked True Value Hardware and Home Depot yesterday looking for a self centering punch. At both stores, I had to explain what it was. Neither had one or at least the clerks couldn't find it. Went to Lowes and found the Stanley shown below. The associate took me right to it without my having to explain what it was. I also purchased the Hitachi self centering drill bit but wouldn't recommend it. It will only drill about 3/8 in. deep. It's intended for door hinges which use short screws.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06180.jpg

Used the punch to mark the bridge mounting holes.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06193.jpg

What's the reason for the cut in the pickup hole? Did he install a slightly too big pickup?

Although routed for a humbucker, the SX came with a single coil. I had to enlarge the pickup rout to get my home made pickguard in position. If you get an SX with a humbucker, the pickup may be a little further forward in the pickguard.

I think Nick meant the cut on the bridge down the lower part of the PU



......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06193.jpg

What will you be using for a preamp?

I think Nick meant the cut on the bridge down the lower part of the PU

Ah ......... my mistake. Don't know why. I'm pretty sure the original was intentionally cut. Don't think it could have cracked.

I'll use some sort of pre-amp circuit but probably not the one the Custom Shop used. Trying to keep the cost down on this project.

I'll use some sort of pre-amp circuit but probably not the one the Custom Shop used. Trying to keep the cost down on this project.

I read in another thread that the Custom Shop Summers Tele just uses the board from the Clapton mid boost. But they wire it as a preamp somehow?

I think that Clapton circuit board is available but it costs over $100. Not in the budget at this time.

Found some old saddles in my parts box. Here's my attempt at turning them into a semi-correct looking saddle. If these don't work out or if I screw them up maybe I can make some out of brass stock.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06210.jpg

Jack, guitar fetish do a clapton mid boost board for $49.95.
http://www.guitarfetish.com/Onboard-Preamp-Clapton-Mid-Boost-Brian-May-Treble-Boost-Clean-Gain_p_571.html.
would this work?

Here's a Clapton kit on Ebay... $54 and change with free shipping

http://www.ebay.com/itm/Fender-Eric-Clapton-Mid-Boost-Preamp-Kit-Brand-new-/230518928273

Nice work on the saddles. I can't really tell from the photos but are they brass inside and you could use something to remove the plating? I would think almost all bridges and saddles would be brass for its ease of machining.

But then again, I was pricing out brass stock recently for making my own bridges... its some spendy stuff. I can't even find brass angle stock in a size that would work for building a bridge.

Thanks for the links guys. I'll check them out. Saddles aren't brass. Appear to be pot metal. I'll use them for now ......maybe make some brass ones later.

Here's my setup for drilling the saddles.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06211.jpg

Here's the set.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06216.jpg



As mentioned earlier, it appears I have a two tone sunburst........ red and black.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06176.jpg

I need a three tone so I remove some of the red from the center.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06214.jpg

Started the coloring of the bridge.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06213.jpg

Tried a little quick experiment with sunbursting. I'm not happy with the result....... too much black. I'll probably redo it.

......http://img.photobucket.com/albums/v208/jwells393/Replica%20Guitar/DSC06215.jpg

Very cool so far, no matter what direction you go it's bound to turn out great!

This looks like it's coming along great it has been very insightful.

Fascinating post. Thanks for sharing.

How's this one going, Jack?

Subscribed! This looks great!

Bump, binding, new finish?

Very inspirational!

Bumping this thread just to see if this one ever turned out... it was one of my favorite builds!

I still ask myself why Jack kinda disappeared.