sjohnbruton's Former Challenge Build

O.k. - Here goes nothin...

I've been lurking here for long enough. Time to make some sawdust. While I have no illusions of winning, I am glad for the well timed motivation provided by the Challenge. I most likely would just continue planning (procrastinating) my first future build if it not for this opportunity.

I'm looking forward to putting all the great info available on the TDPRI to some (hopefully) good use.

I hear ya. I'm kind of in the same boat. This challenge got me to clean up my shop & finish the walls. I think I won already. My plan is just to build a guitar I want and watch all the other threads. Best of luck to you.

Not much progress yet, but I'm getting ready. "Proof of Life" photos coming soon.

Since I am using this Challenge as motivation to begin building real guitars, I have some prep work to do.

Things to Do:
1. Clean out shop space and set up for woodworking.
2. Finish gathering supplies for build.
3. Complete my body and neck templates.
4. Build a router/ planer jig.
5. Make a fretboard radius jig.
6. Make sawdust. And (hopefully) a working guitar.

Nothin to it, right?

Step 1. - "Clean out shop space and set up for woodworking."
This one is the main reason I haven't already started making guitars. I hate cleaning. Photos to follow soonish.

Good luck and welcome to the challenge.

Step 7 - apply finish.
Step 1 would be the hardest for me.
Good luck.

Good luck and welcome to the challenge.

Thanks. I'll need it!

Step 7 - apply finish.
Step 1 would be the hardest for me.
Good luck.

Oh Yea. Step 7. I'm thinking about solid color spray can cream. And yes, Step 1 will be the hardest.

O.K. - here goes!

Steps 1 through 5 are starting to happen simultaneously. The shop cleaning process will take a while. Photos to follow.

Here are the specs of the guitar I plan to build:
1. Either a Pine and Poplar body, or an all Poplar body - haven't decided yet, but I'm leaning toward the Pine/ Poplar just because it will lend itself better to the materials I have on hand.

2. An Oak neck with a Poplar fretboard. - I know, I know... this boarders on blasphemy with some folks, but again, it is what I have on hand.

3. Cream solid color paint finish, White pick guard, Chrome hardware (with ashtray).

4. Fender Baja Tele pickups and electronics on a Reverse control plate.

Entering the Pit of Doom.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-01.jpg

As you can see, Step 1. is no small task.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-02.jpg

This shop is attached to the back of our carport and has collected junk for the last 12 years. Right now, it is easier to move one of the cars and work in the carport than actually try to work in the shop. Sad but true.

Here is the repurposed potting bench now seeing duty as a work bench.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-02-2.jpg

Good luck with your build and cleaning out the shop. I've been working on that too.

The mandatory proof of start shots.

Here is my stack of Poplar boards, a 1" thick Pine table top, and various other pieces that may make an appearance in this build.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-05.jpg

The templates from Step 3 that need finishing.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-07.jpg

My unfinished neck templates and the oak board that will become a neck. Or two.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-08.jpg

A word now about the neck that will be on this build. I don't plan on using it for much more than practice. I need plenty of practice and I don't really need the neck.

You see, I have an excellent 22 fret Warmoth tele neck with abalone dots that a friend gave to me several years ago. It has been patiently waiting for a body to join with. Once this build is done, I will put the Warmoth neck on.

So, this build neck will be oak with a poplar fret board. Oh, and it won't have an adjustable truss rod. The plan is to put in an aluminum T-bar to strengthen the oak. I'm pretty sure the oak, poplar, aluminum combo will be stiff enough to last quite a while.

Great start and be careful, you may find out you like the necks you build a whole lot
better than the ones Warmoth does, lol. You probably should be looking for more body
material for that neck, lol.

This is me using a drill mount and an 80 grit sanding drum to rough sand the contours.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-09.jpg

Here I'm pattern bit routing the straight edges with the board as a guide.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-10.jpg

And the (mostly) done neck templates.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-11.jpg

These photos are from yesterday. This afternoon, I finished sanding all the contours by hand. Sorry no photo. Ready to make a neck!

Good luck with your build and cleaning out the shop. I've been working on that too.

Thanks. I'm looking forward to the build. The shop is just a four plus mess.

Great start and be careful, you may find out you like the necks you build a whole lot
better than the ones Warmoth does, lol. You probably should be looking for more body
material for that neck, lol.

Yeah, I've thought about that. Frankly, I have about six builds rattling around in my head right now. One at a time for now, though.

Today was Template Day. You know... the day when hand shaped 1/4 inch master templates graduate to become 3/4 inch working templates.

The collected class of 2012. I decided to go ahead and finish my LP and Strat templates while I was working on my Tele neck.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-12.jpg

Ready to rough out the working templates with my trusty OLD jig saw.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-13.jpg

Rough cut and ready for the bandsaw.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-14.jpg

After the bandsaw (sorry no pics), I attached the master templates to the rough cut working templates. On to the router table...

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-15.jpg

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-16.jpg

After the router. Lookin' sharp!

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-17.jpg

After using the pattern bit to rout my working templates, I have a few places like this...

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-18.jpg

I'm guessing that either the master template had a minor flaw that was magnified by the pattern bit, or (more likely) my router technique needs work.

Anybody know how to fix this? I don't really want to redo the entire template from scratch. My first thought is CNA glue to fill, then sand to shape. Any thoughts?

Anyway, on with the show. Next I set up to spray the lot with clear laquer to seal the MDF.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-19.jpg

Mobile, AL is an incredibly humid environment, so in an effort to make these puppies last as long as possible, I thought to protect them a bit.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-20.jpg

That's it for today. On our next episode... Pattern sanding an oak neck blank with the Robo-Sander.

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/cb12-21.jpg

Anybody know how to fix this? I don't really want to redo the entire template from scratch. My first thought is CNA glue to fill, then sand to shape. Any thoughts?

You've already know how, but don't realize it. You know how you used a board with your pattern bit to make the master? Take that board (or your oak one) and clamp to the edge of this assembly slightly (very slight) offset enough to clean up that edge. You'll repair both templates at the same time :wink:

Dave

That is the coolest drill press I have seen in a long time!

You know how you used a board with your pattern bit to make the master? Take that board (or your oak one) and clamp to the edge of this assembly slightly (very slight) offset enough to clean up that edge. You'll repair both templates at the same time :wink:

Dave

Thanks Dave. I like that idea. It will have to be a different board though. I've already cut that oak one into two neck blanks! :shock:

That is the coolest drill press I have seen in a long time!

Thanks. The best I can figure, it's a 1956 Delta Homecraft and it's HEAVY. I bought it from a music store owner that closed his doors last spring. He was going out of business, so I went in to ask if he had any guitar repair tools he wanted to get rid of. I missed out on most of his tools, but the I got the drill press, the handheld router I was using earlier in this thread, and a huge box of pickups and parts for $125! The box of parts and pickups turned out to have very few usable parts, but there were nearly 100 used pickups of various styles and quality!

I dented a few of my templates just like that. I fixed then with 2 part wood filler and sanded flat.
How do you like your robosander. I have one and love it.

I dented a few of my templates just like that. I fixed then with 2 part wood filler and sanded flat.
How do you like your robosander. I have one and love it.

Is that 2 part wood filler an epoxy? I've never used it.

The Robo-Sander is fresh out of the box, so I can't say how I like it yet. But, I'm pretty sure I will. I bought it after reading several preeb threads and seeing him sand down his blanks before routing them with a spiral flush cut bit.

A lot of people will use Durhams rock hard water putty to fill and re-sand spots like that

Your templates look good, and good idea to protect them
from humidity. In case you didn't know, shellac provides
an excellent barrier to water vapor, so it can also be used.
It's easy to just wipe on and it's not toxic like lacquer.

My theory is that those little router "indents" are caused
by bumping the work slightly at the beginning of a router
pass. I seem to be able to avoid them by moving into
the work very gently.

A lot of people will use Durhams rock hard water putty to fill and re-sand spots like that

I may have to try that. I've heard of several people here recommend it. Thanks.

Your templates look good, and good idea to protect them
from humidity. In case you didn't know, shellac provides
an excellent barrier to water vapor, so it can also be used.
It's easy to just wipe on and it's not toxic like lacquer.

My theory is that those little router "indents" are caused
by bumping the work slightly at the beginning of a router
pass. I seem to be able to avoid them by moving into
the work very gently.

I didn't know that about shellac. Thanks.

I kinda figured those marks were the result on my lack of experience/ technique. Oh well, fixing mistakes is how you get experience.

No progress today. Unless you count backward progress.

Broke the blade on my 9" benchtop Ryobi band saw. Crap! No body blank action until I get a new one. I think I need to read the manual on blade adjustment again...

The wood filler I use is a 2 part epoxy. I have also used J-B Weld. That is great stuff. I always have it around the shop.

A little progress today. I got a new blade for the bandsaw (I hope it's the right one) and finished the layout on my neck template.

Next up, drill the pilot tuner holes on the template, attach to my neck blank, and robo-sand to shape.

A bandsaw with a fresh blade is a mans pride and joy!
Nice set of templates.

Nice set of templates.

Thanks.

If it weren't for stupid distractions like a job, I would work on this thing all the time!

Yeah those job-things tend to constantly get in the way.

Wow! The builds going on around here are flat awesome!! I am really enjoying all the killer ideas flying around here! I wish I could say the same about mine...:neutral:

Minor update - since I am out in left field with my chosen (hardware store) materials anyway, I've decided to change my exotic poplar top for something a bit more "run of the mill."

Ever since I played a late fifties Silvertone (and it's owner refused to sell it to me), I have wanted a Danelectro style guitar. So, I'm using a hand selected AAA piece of manufactured "wood product" for the top and back of my build.

The design will still feature a 1" thick pine center like before, but now I plan to paint the whole thing, neck and fretboard included. I'm aiming for something in the region of a pale blue?

Pale blue looks nice really lends to the retro look in my mind anyways. Never seen a painted fingerboard before that would be interesting.

I gotta say that's one hell of a drill press you have there looks like it has some serious UMMPH!. If the world were ever to stop spinning on its own i bet you could mount that on the north pole and get the job done. :lol:

The design will still feature a 1" thick pine center like before, but now I plan to paint the whole thing, neck and fretboard included. I'm aiming for something in the region of a pale blue?

That sounds awesome!!!
I can't wait to see it.

Pale blue looks nice really lends to the retro look in my mind anyways. Never seen a painted fingerboard before that would be interesting.

I gotta say that's one hell of a drill press you have there looks like it has some serious UMMPH!. If the world were ever to stop spinning on its own i bet you could mount that on the north pole and get the job done. :lol:

Thanks. Interesting is a good word for this idea. I hope it works...

Anybody got any tips for painting a fretboard??

As for the drill press, I enjoy looking at it almost as much as I enjoy using it to make holes in things. :grin:

Weird thing about that drill is that it is very quiet. I like it.

That sounds awesome!!!
I can't wait to see it.

Me too! I hope I can continue to make time to work on it...

Since I'm heading this way, I need an appropriate logo. Let's put it to a vote (sort of):

Danecaster or Jonelectro?

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/BrutonDanologoBW.jpg

And in the reverse:

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/BrutonDanologowhite.jpg

What say ye?

thou shalt be called jonelectro and the commoners shall rejoice.

That's my vote, very cool decal.

thou shalt be called jonelectro and the commoners shall rejoice.

That's my vote, very cool decal.

Thanks... You are correct: "thou shall be called Jonelectro!"

I don't know about the commoners, though.

Well... build progress has slowed to below a crawl. A major family illness has necessitated a "quick" trip to Houston. Cancer sucks, by the way. :sad:

As for the build, the vision has cleared and a plan is in action! A Tele body shape, built w/ Dano methods.

Features:

A solid 1"pine table top from HD will be the core. 1/4" MDF or Masonite will be the top and back. It will be 1.5" thick and light! Inards to look like this:

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/danoproject1.jpg

It will have a soundhole and pickup configuration like the Dano Convertible, like this:

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/convertible.jpg

The pickguard is a hybrid of Tele thinline and Dano 59 "seal" guard, like this one:

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/danelectro-59-dc-bk-1.jpg

And so the Jonelectro will look very similar to this:

http://i1082.photobucket.com/albums/j371/sjohnbruton/challenge%20build%202012/Jonelectrov4side.jpg

It will be fully painted, vinyl binding tape around the body, Fender style nut in aluminum (like a Dano), and a hybrid Dolphin nose/ Tele headstock!

I like it! Now I just have to build it. :wink:

Best of luck to your family member with cancer. Yes, cancer does really suck, I can empathize. It is amazing what the body can recover from, given time, patience and caring - I hope it is a situation like that.

On the flip side, it turns out guitar building is very therapeutic, making some time for yourself each day to get some progress done is not a selfish thing, and may allow you to get grounded and blow off some tension making some sawdust. Best of luck to you and your family. And, have fun with your build.

That is a very cool plan!

Best wishes to you and your family on the fight with cancer.

Good plan for the build and best wishes with the family illness .

Best of luck to your family member with cancer. Yes, cancer does really suck, I can empathize. It is amazing what the body can recover from, given time, patience and caring - I hope it is a situation like that.

On the flip side, it turns out guitar building is very therapeutic, making some time for yourself each day to get some progress done is not a selfish thing, and may allow you to get grounded and blow off some tension making some sawdust. Best of luck to you and your family. And, have fun with your build.

That is a very cool plan!

Best wishes to you and your family on the fight with cancer.

Good plan for the build and best wishes with the family illness .

Thanks everyone for the well wishes. My father-in-law needs all the prayers he can get at this point.

As for the build, I agree it is very therapeutic to create. Whether it is making guitars or making music, it feels good. I may not finish during the challenge, but I look forward to plugging it in and cranking it up!

All the best for your father-in-law and the family in general, it can be a really stressful time.

In terms of the build, I think that's a really well executed plan - a hybrid that really works. It's clever but doesn't feel too forced. Well done. All the best - I'm staying tuned.

All the best for your father-in-law and the family in general, it can be a really stressful time.

In terms of the build, I think that's a really well executed plan - a hybrid that really works. It's clever but doesn't feel too forced. Well done. All the best - I'm staying tuned.

Thanks.

Well, it was painfully obvious before, but now it's official. I'm out. :sad:

To much life happening right now... And not enough calendar.

I'll be moving this thread over to the Tele Home-Depot soon. I'm psyched about getting this one built.

Well, it was painfully obvious before, but now it's official. I'm out. :sad:

To much life happening right now... And not enough calendar.

I'll be moving this thread over to the Tele Home-Depot soon. I'm psyched about getting this one built.
Looking forward to it! :smile:

God bless and keep you all,



Dave

Your former build thread has been moved to the Tele Home Depot Forum.