![$vboptions[bbtitle]](../../gifs/tdpr-headTRANS.gif)
andrewdoeshair
July 2nd, 2012, 09:39 PM
I started with this giant pile of wood and a jointer (http://www.lowes.com/ProductDisplay?partNumber=80877-70-PC160JT&langId=-1&storeId=10151&productId=3059865&catalogId=10051&cmRelshp=rel&rel=nofollow&cId=PDIO1)
http://distilleryimage2.s3.amazonaws.com/9be5e3509b3a11e180d51231380fcd7e_7.jpg
This build is my first in a few months (been busy cutting lots of hair) so I used some of the less attractive wood I had in stock, in case I'm a little rusty...
http://distilleryimage3.s3.amazonaws.com/6b0e3b96c3fe11e1b10e123138105d6b_7.jpg
Two PVC pipes, mounted to a flat board, will support a long flat sled with a router (http://www.amazon.com/Porter-Cable-690LR-11-Amp-Fixed-Base-Router/dp/B00005QEVQ) mounted on top. The router has a 1.25" diameter bit with a flat bottom (http://www.amazon.com/Magnate-Surface-Planing-Bottom-Cleaning/dp/B0006B0PX0), so I can take passes over the blank to remove about 1/16" of material on each pass. The blank is secured to this flat board by suction, through holes beneath the blank, and the use of a 2hp dust collector (http://www.harborfreight.com/garage-shop/stationary-dust-collectors/2-hp-industrial-5-micron-dust-collector-97869.html). After the one side is made flat, it is flipped over and taken to the final thickness. For this body, I went with 1.625" like a typical Jaguar.
http://distilleryimage1.s3.amazonaws.com/82bfed48c47111e19b0622000a1e8a4f_7.jpg
The template is affixed to the blank using short drywall screws, in areas that will be removed or hidden when the guitar is completed. I like to screw it down before I trace anything, to make sure it screws into place exactly where it was when traced. After tracing my template (an amalgamation of these (http://www.ponoko.com/showroom/PaulRhoneyGuitarCo/products)) I use a band saw (from harbor freight, which is apparently discontinued) to cut very close to the outside line. The closer I get, the less material I'll have to rout off later.
http://distilleryimage5.s3.amazonaws.com/cee5f33ec47111e1be6a12313820455d_7.jpg
I use a Forstner bit (http://www.rockler.com/product.cfm?page=10615) in a drill press (http://www.lowes.com/pd_78742-46069-PCB660DP_4294857557__?productId=3162489&Ns=p_product_qty_sales_dollar%7C1&pl=1¤tURL=%3FNs%3Dp_product) to remove most of the material from within the cavities.
http://distilleryimage6.s3.amazonaws.com/f99ec470c47111e1bef722000a1e8bb5_7.jpg
The template is then affixed to the blank again, and a giant, scary, dangerous router bit (http://www.ebay.com/itm/Flush-Trim-Router-Bit-2-1-2-Long-Cutter-w-Top-Bottom-Bearing-Yonico-14135-/220955194759?pt=Routers_Bits&hash=item3371f4b587#ht_3168wt_1398) is used to shape only the "downhill" cuts...
http://distilleryimage10.s3.amazonaws.com/2bee0526c47211e1ba8122000a1d0135_7.jpg
The whole thing is flipped over, and the bit is raised, so that the rest of the body can now be trimmed in the proper "downhill" direction. Become VERY confident, and respectful of your tools before you try to use a bit like this one. If you're afraid of it, forget about it. This thing will make finger soup in an instant.
http://distilleryimage3.s3.amazonaws.com/4c33bc36c47211e1aaec22000a1e88af_7.jpg
I own 3 of the routers I have linked above, because it saves 10+ minutes per body to not have to change bits between each process. I hate changing bits... To clean up the cavities, I used a 1/2" pattern bit (http://www.amazon.com/Freud-50-102-2-Inch-Bearing-Flush/dp/B0000225XQ/ref=pd_bxgy_hi_img_b). I ended up swapping a few templates around to get what I wanted for this guitar... Oh, BTW, these bench cookies (http://www.rockler.com/product.cfm?page=30951) are phenomenal.
http://distilleryimage4.s3.amazonaws.com/78d0e3f4c47211e1a38422000a1c8933_7.jpg
The round over was done with a 1/2" radius bit (http://www.amazon.com/Freud-34-126-Quadra-2-Inch-Rounding/dp/B0000225WS/ref=pd_cp_hi_1), although Fender used to use a 7/16"...
http://distilleryimage7.s3.amazonaws.com/e74ff9b0c47b11e1b00112313800c5e4_7.jpg
Back to the band saw to rough out the contours. These are cleaned up with a 3" drum on the oscillating spindle sander (http://www.harborfreight.com/oscillating-spindle-sander-95088.html).
http://distilleryimage3.s3.amazonaws.com/fd32505cc47b11e19c6622000a1e89ba_7.jpg
The pickguard was made from B/W/B material, purchased from guitarfetish.com, rough cut on the band saw, flush trimmed with a 3/8" bit, then beveled with a 45 degree chamfer bit...
http://distilleryimage4.s3.amazonaws.com/1f5a2ba0c47c11e1b2fe1231380205bf_7.jpg
And in the end it looks about like this...
http://distilleryimage10.s3.amazonaws.com/7840b0d6c47c11e19894123138140d8c_7.jpg
http://distilleryimage10.s3.amazonaws.com/a1312c14c47c11e1aee522000a1e8a5f_7.jpg
Just needs sanding... I'll let the buyer do that...
Next week: a guitar made from a two by four!
http://distilleryimage5.s3.amazonaws.com/1f2ff8cec48811e1a8761231381b4856_7.jpg
http://distilleryimage2.s3.amazonaws.com/9be5e3509b3a11e180d51231380fcd7e_7.jpg
This build is my first in a few months (been busy cutting lots of hair) so I used some of the less attractive wood I had in stock, in case I'm a little rusty...
http://distilleryimage3.s3.amazonaws.com/6b0e3b96c3fe11e1b10e123138105d6b_7.jpg
Two PVC pipes, mounted to a flat board, will support a long flat sled with a router (http://www.amazon.com/Porter-Cable-690LR-11-Amp-Fixed-Base-Router/dp/B00005QEVQ) mounted on top. The router has a 1.25" diameter bit with a flat bottom (http://www.amazon.com/Magnate-Surface-Planing-Bottom-Cleaning/dp/B0006B0PX0), so I can take passes over the blank to remove about 1/16" of material on each pass. The blank is secured to this flat board by suction, through holes beneath the blank, and the use of a 2hp dust collector (http://www.harborfreight.com/garage-shop/stationary-dust-collectors/2-hp-industrial-5-micron-dust-collector-97869.html). After the one side is made flat, it is flipped over and taken to the final thickness. For this body, I went with 1.625" like a typical Jaguar.
http://distilleryimage1.s3.amazonaws.com/82bfed48c47111e19b0622000a1e8a4f_7.jpg
The template is affixed to the blank using short drywall screws, in areas that will be removed or hidden when the guitar is completed. I like to screw it down before I trace anything, to make sure it screws into place exactly where it was when traced. After tracing my template (an amalgamation of these (http://www.ponoko.com/showroom/PaulRhoneyGuitarCo/products)) I use a band saw (from harbor freight, which is apparently discontinued) to cut very close to the outside line. The closer I get, the less material I'll have to rout off later.
http://distilleryimage5.s3.amazonaws.com/cee5f33ec47111e1be6a12313820455d_7.jpg
I use a Forstner bit (http://www.rockler.com/product.cfm?page=10615) in a drill press (http://www.lowes.com/pd_78742-46069-PCB660DP_4294857557__?productId=3162489&Ns=p_product_qty_sales_dollar%7C1&pl=1¤tURL=%3FNs%3Dp_product) to remove most of the material from within the cavities.
http://distilleryimage6.s3.amazonaws.com/f99ec470c47111e1bef722000a1e8bb5_7.jpg
The template is then affixed to the blank again, and a giant, scary, dangerous router bit (http://www.ebay.com/itm/Flush-Trim-Router-Bit-2-1-2-Long-Cutter-w-Top-Bottom-Bearing-Yonico-14135-/220955194759?pt=Routers_Bits&hash=item3371f4b587#ht_3168wt_1398) is used to shape only the "downhill" cuts...
http://distilleryimage10.s3.amazonaws.com/2bee0526c47211e1ba8122000a1d0135_7.jpg
The whole thing is flipped over, and the bit is raised, so that the rest of the body can now be trimmed in the proper "downhill" direction. Become VERY confident, and respectful of your tools before you try to use a bit like this one. If you're afraid of it, forget about it. This thing will make finger soup in an instant.
http://distilleryimage3.s3.amazonaws.com/4c33bc36c47211e1aaec22000a1e88af_7.jpg
I own 3 of the routers I have linked above, because it saves 10+ minutes per body to not have to change bits between each process. I hate changing bits... To clean up the cavities, I used a 1/2" pattern bit (http://www.amazon.com/Freud-50-102-2-Inch-Bearing-Flush/dp/B0000225XQ/ref=pd_bxgy_hi_img_b). I ended up swapping a few templates around to get what I wanted for this guitar... Oh, BTW, these bench cookies (http://www.rockler.com/product.cfm?page=30951) are phenomenal.
http://distilleryimage4.s3.amazonaws.com/78d0e3f4c47211e1a38422000a1c8933_7.jpg
The round over was done with a 1/2" radius bit (http://www.amazon.com/Freud-34-126-Quadra-2-Inch-Rounding/dp/B0000225WS/ref=pd_cp_hi_1), although Fender used to use a 7/16"...
http://distilleryimage7.s3.amazonaws.com/e74ff9b0c47b11e1b00112313800c5e4_7.jpg
Back to the band saw to rough out the contours. These are cleaned up with a 3" drum on the oscillating spindle sander (http://www.harborfreight.com/oscillating-spindle-sander-95088.html).
http://distilleryimage3.s3.amazonaws.com/fd32505cc47b11e19c6622000a1e89ba_7.jpg
The pickguard was made from B/W/B material, purchased from guitarfetish.com, rough cut on the band saw, flush trimmed with a 3/8" bit, then beveled with a 45 degree chamfer bit...
http://distilleryimage4.s3.amazonaws.com/1f5a2ba0c47c11e1b2fe1231380205bf_7.jpg
And in the end it looks about like this...
http://distilleryimage10.s3.amazonaws.com/7840b0d6c47c11e19894123138140d8c_7.jpg
http://distilleryimage10.s3.amazonaws.com/a1312c14c47c11e1aee522000a1e8a5f_7.jpg
Just needs sanding... I'll let the buyer do that...
Next week: a guitar made from a two by four!
http://distilleryimage5.s3.amazonaws.com/1f2ff8cec48811e1a8761231381b4856_7.jpg