CNC Broadcaster build...and then some!

[ehawley]

Originally Posted by jwells393

Since you're not exactly building it the way they did back then, I wouldn't purposely mis-align the ferrule holes.

Do I see a slight mistake in one of the pictures?

Good point...Which picture? I had a slight chip at the neck pickup, is that it?

Cheers
ED

[jwells393]

I was referring to what appears to be a misplaced bridge mounting hole.........maybe it has another purpose.

How long does it take to cut the cavities......... for instance how long for the bridge pickup cavity?

[ehawley]

Originally Posted by jwells393

I was referring to what appears to be a misplaced bridge mounting hole.........maybe it has another purpose.

How long does it take to cut the cavities......... for instance how long for the bridge pickup cavity?

HAHA!....You saw that! If you look at the full front view you will see other holes that look misplaced also. To the left of the neck pickup, to the right of the lower control mounting hole...Those are my locations for the nails for painting the sides and back of the guitar...Same way Fender did it! If you remember the painting of the body in the 53 build, I put it on the "nails" to paint it.





53 build pics of the nails and body on the "lazy susan"


This guitar took about 38 min to cut. after it was cut to thickness. I'm getting faster!
Cheers
ED

[Nick JD]

Here's a loop I writed to run though your 'puter that makes the ferrule holes look like Leo drilled them.

while (aBitDrunk = true) {

x = aBitToTheLeft;
y = aBitToTheRight;
z = faGetaBoutIt;

for(something; meh; x++){
drill(x, y, z);
return();
}
}

[jwells393]

Ah ..............I understand now. I refinished a 1960 Strat once. It had the nail holes and I used them.

[ehawley]

Originally Posted by Nick JD

Here's a loop I writed to run though your 'puter that makes the ferrule holes look like Leo drilled them.

while (aBitDrunk = true) {

x = aBitToTheLeft;
y = aBitToTheRight;
z = faGetaBoutIt;

for(something; meh; x++){
drill(x, y, z);
return();
}
}

I'll have no problem doing that!!?!

Hey Nick...here's my little touch of Australia..My blind Silky Terrier named Matilda....



Cheers
ED

[Nick JD]

She's cute! Are they cataracts?

[ehawley]

Originally Posted by Nick JD

She's cute! Are they cataracts?

yup...we went to have them removed but she also had retinal problems so they wouldn't operate She's a small one as far as silkys go. Only 6 lbs.
She gets around fine....inside, outside...Still chases squirrels by the sound of them running. They give her no respect!!
Cheers
ED

[Edutainment]

I've never seen a CNC build. This should be interesting.

Originally Posted by ehawley

Cute puppy. Was she born blind?

[blacklove]

Again, super build! The ferrule dilemma (perfect vs. hand-done) would be a hard decision for me. Good luck!

[daviddoubleu]

Fantastic build thread, thanks again for sharing.

[ehawley]

My pleasure guys ...hey blacklove... the name and logo are coming into play again! I'm calling this one the "JERSEY BROAD".. .. My wife had something to say about that!
Edutainment...she went blind about 6 years ago. She is already 15!

I just finished roughing out the back of the "veneer" neck. Pics will be posted tonight!
Cheers
ED

[ehawley]

The back of the verneer neck has been cut. This is not the neck that will be going on the broadcaster. This is a neck I am making to replace a neck on one of my other guitars.I thought that it would be interesting to do because you don't see anyone making these much. It differs from a slab rosewood neck in that the fingerboard is a thin piece of verneer glued to a curved maple top.The markers and side dots are MOP. Fender used this method in the 60s'. There is no skunk stripe on the back of the neck because the truss rod is inserted in a slot under the fingerboard. This result is one of the nicest looking necks in my opinion.

The raw board is double faced taped to the machine to flycut it flat.
This is an end cut from the board, hence the raw area along the edge.





Once the board is flycut it is flat and I can flip it over to start the machining on the other side.



the board is flipped and a test cut is made to check the fit. I don't need it running off the piece!!



I'm ready to begin cutting.

[ehawley]

The outer shape of the neck is cut





Using a .750 ball endmill the back of the neck is roughed out.

[ehawley]

With the back roughed out I drill the mounting holes. Because I make the bodies also, I can pre-drill the mounting holes in the neck and they will be perfectly aligned. I also drill the "template" holes.



With the neck done I pop it off



Some finished flame shots!





There is still alot of hand shaping to be done on the headstock. But that is the fun of it!! I have to do some things by hand!
I still have to cut the top side and route for the truss rod. I won't cut the top radius until I pick the verneer. I want a 9.5 radius on the neck so I have to cut the radius on the maple 9.5 - the thickness of the verneer. I have to get the verneer first.
I'm off to Willard Bros. thursday to pick out the rosewood verneer for the finger board. I'll have pics when I get it. In the mean time I will be routing the radius on the body and doing alot of sanding. Pics of that to come!
Cheers
ED

[ehawley]

Just for kicks I put the neck on the broadcaster body.



Cheers
ED

[jwells393]

Oh man ............... it just doesn't seem fair.

[ehawley]

Originally Posted by jwells393

Oh man ............... it just doesn't seem fair.

Yeah, but your most likley in better shape than me....I just stand there and watch this thing work like a "couch potato"

Thanks Jack
Cheers
ED

[Taipan]

Originally Posted by ehawley

Ed,
Noticed that you used the same size and length end mill ( 1/4" 4- flute ) for the body. Are you using a certain type of helix to minimize your deflection or just minimizing the depth of your cut until you get to the finish pass?

[ehawley]

Originally Posted by Taipan

Ed,
Noticed that you used the same size and length end mill ( 1/4" 4- flute ) for the body. Are you using a certain type of helix to minimize your deflection or just minimizing the depth of your cut until you get to the finish pass?

The endmill I use for the body and neck is a 1/4 solid carbide 4 flute high helix type used for fast cutting of aluminum. I climb mill (move in the direction that the cutter is turning) so the deflection, if any, is away from the piece. I take an extra pass at the end to clean up. Each cut is .300 deep anywhere from 4000 to 7000 RPM, anywhere from 40 IPM to 100 IPM. It depends on how the wood is cutting. Ash is a pain because it likes to chip and pull out. I'll take some extra time with the first cut to make sure it's clean. After the inital cut is when I speed it up. Maple is no problem.
Thanks
Cheers
ED

P.S. I used to use a 2 flute...you could cut faster and higher RPM, but for some reason the finish wasn't as clean and there was more tear out in the ash!

[Gaber_771]

these builds are awesome Ed, Thanks Again!!!

[ehawley]

Originally Posted by Gaber_771

these builds are awesome Ed, Thanks Again!!!

Thanks Gaber...



The weight of the body is just a hair under 5 lb (4lb 15 1/2 oz to be exact) The guitar should come in just under 8 lb. Most of the ones I build come in around that mark. Not too heavy and not to light! Right in the middle of the "Tone" range!.. ..
Cheers
ED

[milocj]

I can't contribute much to this thread other than that I love watching builds like this, especially since I design automotive tooling on the computer all day so it's nice to see things actually being built.

I'll just drop in a gratuitous picture of my soldering buddy Milo to help tie in with the sidebar in this thread.

[Joisey]

Originally Posted by ehawley

My pleasure guys ...hey blacklove... the name and logo are coming into play again! I'm calling this one the "JERSEY BROAD".. .. My wife had something to say about that!

Love the name! Although a Jersey broad takes a bite out of my pay check every two weeks. Now I feel sick. Love the Name! Thanks for the build progress.

[Danno]

Amazing as always Ed. You're very generous taking the time to take the pictures and provide all the details. Hopefully soon I'll take advantage of our CNC machine's down in our plant using one of your files. You've done an incredible amount of "footwork" with the files you created. Much appreciated. I imagine many hours were involved.

Dan

[ehawley]

Originally Posted by milocj

I can't contribute much to this thread other than that I love watching builds like this, especially since I design automotive tooling on the computer all day so it's nice to see things actually being built.

I'll just drop in a gratuitous picture of my soldering buddy Milo to help tie in with the sidebar in this thread.

Yorkie? Nice!

Originally Posted by Joisey

Love the name! Although a Jersey broad takes a bite out of my pay check every two weeks. Now I feel sick. Love the Name! Thanks for the build progress.

New Jersey it self takes a bite out of us all!! (hidden taxes!!)

Originally Posted by Danno

Amazing as always Ed. You're very generous taking the time to take the pictures and provide all the details. Hopefully soon I'll take advantage of our CNC machine's down in our plant using one of your files. You've done an incredible amount of "footwork" with the files you created. Much appreciated. I imagine many hours were involved.

Dan

Thanks Dan...anything you need for the machining just let me know!

Cheers all
ED

[axmaker]

Originally Posted by Joisey

Love the name! Although a Jersey broad takes a bite out of my pay check every two weeks. Now I feel sick. Love the Name! Thanks for the build progress.

i have a jersey broad too.....

[Preacher]

The boss just put an order in on a $150,000.00 Onsrut CNC router multi machine for use in the shop.

Now I am setting here thinking about starting Tele body drawings instead of working on what I am supposed to be working on...

[ehawley]

Originally Posted by Preacher

The boss just put an order in on a $150,000.00 Onsrut CNC router multi machine for use in the shop.

Now I am setting here thinking about starting Tele body drawings instead of working on what I am supposed to be working on...

Once you start...you can never go back..or make enough of them!..

[Superc_1]

Ed, I know I'll be like everybody else on the site, and can't wait till the next post. I'm honored to be able to contribute in some small way. Your builds inspire everybody on this forum in one way or another. Man o' man those are going to be some sweet looking axes when its over. Hot diggie dog. Later and Cheers!

[rhh7]

Your neck is awesome!

[Echoplex]

I just love these threads.Great work!

[Gabriel_GR]

So, let's say I brought you 10 correctly cut blank's, how many bodies could you accurate produce in let's say a week?

I have access to a CNC and talked to other friends about the possibility to cut bodies. I am wondering, once you have the map, how easy and fast it is?

[Shepherd]

Makes me feel like a caveman rubbing two sticks together.

[telechucker]

Real inspiring thread - Thanks !

[ehawley]

Hi all...Been very busy at work the past 2 weeks! I haven't had much time for building!! BUT...I went to Willard Brothers today to pick out fingerboard wood for the verneer necks. The rosewood selection wasn't much this time around but there was a super selection of Macassar Ebony. I always liked ebony for a fingerboard. Macasser ebony has colors anywhere from a grey_pink to a dark red_black. A beautiful wood. I picked a piece that was dark red in color. Almost the same color of vintage rosewood. Very dark! Here are a few pictures of my find. The piece was 39" long by 1" thick (a true 1" (5/4)) I cut it in half to 19 1/4 long. I can get 6 fingerboards out of it . If I want to take the time and REALLY set up my band saw for re-sawing, I may be able to get 4 pieces from each blank, but I think I'll play it safe and get 3!!

Here is a picture of what I consider heaven! Willard Bros. exotic shed!!



Here is a shot of the ebony...



Nice straight tight grain...



I cut 4 necks out of the piece of flamed maple that Dwight sent me. The ebony will be going on these necks.



Next week I'll be cutting the ebony to glue onto the necks. The finger board side of the necks will be cut for the verneer and the truss rod slot also.
I haven't had time to fill and sand the body yet , but that is coming .
Thanks all
Cheers
ED

[jwells393]

I cut 4 necks out of the piece of flamed maple that Dwight sent me.

Four necks? .............. I'm going back to my cave.

[ehawley]

Originally Posted by jwells393

Four necks? .............. I'm going back to my cave.

I think there is alot more going on in your cave then mine right now!! Work is (real work!) keeping my "fun" work in check!

On another note, I'm planing another "RT 66" trip this winter. I'm going to stop along the way and visit fellow TDPRIers. You are on my list if you would like to join me for a few quick ones!?! We'll talk about it when the time gets closer! Alot of you live along that great road!
Cheers
ED

[dougk]

Wow Ed, glad I finally stopped lurking at the right time! Loved watching your thread. I wont lie, I've been using your CAD files on my own CNC (SCM Tech99 if theres woodworkers here) for a while now.

I wish I could get ours to do 3d dimensional better (ie shaping necks), I have to trick it into doing any sort of rough in.

[ehawley]

Originally Posted by dougk

Wow Ed, glad I finally stopped lurking at the right time! Loved watching your thread. I wont lie, I've been using your CAD files on my own CNC (SCM Tech99 if theres woodworkers here) for a while now.

I wish I could get ours to do 3d dimensional better (ie shaping necks), I have to trick it into doing any sort of rough in.

Thanks Doug! Hmm....Sounds like a software thing! PM me and I'll give you my phone #. Lets talk. I might be able to help you with the necks...(G code maybe?)
Cheers
ED