CNC Broadcaster build...and then some!

ehawley · July 6th, 2008, 12:30 PM

Hi all!! Back again for another fun build!

Since my last build thread , I have made alot of new friends all around the world! This is what this site is all about!! It can't get any better then here!. I am a member on other sites but this site is my HOME!! The best!! I have learned alot of new "stuff" , and hope that I have contributed some "stuff" also! Now, let us all step out of the "circle" and get on with the build!

This will be a multi build thread made popular by sparkely Steve ( aka..Buckocaster). It will be a broadcaster build in the traditional sense, also a 60s' verneer neck complete with pearloid markers and maple cap neck thrown in. (I would like to replace some purchased necks with ones that I built myself).

The wood for this build came mostly from my good friend Dwight (aka Superc_1) who I met here. Dwight lives in Arkansas. He aquires some mighty fine wood! He is a great builder also! Some great mandolins and teles!

The inspiration for the truss rod anchor came from Jack (aka jwells393) He sent me a picture of a truss rod anchor which I used to make mine for the broadcaster neck. I altered it abit. I'll explain as we go along.

I will be winding the pickups for this the same way the broadcasters of the 50s were done. 43 guage wire for both the bridge and neck pickups.
Electronics will be the "Blend" control.
Tuners will be Kluson single line. I am also machining the jack cup! Should be fun!

ehawley · July 6th, 2008, 12:31 PM

First, the drawings.....

Here is the Broadcaster body drawing...

Like the first broadcasters, there is no wire channel route under the pickguard. The treble side of the neck pocket is "straight" which will result in the "shelf" showing under the neck.

The Broadcaster neck drawing...

The profile...

not quite a boat (V) neck, nor a "baseball" bat either, but a nice chunky neck.

I made significant changes to this drawing from my originals in my last build!
Another fellow that I met through here was David Eichelbaum. He worked on the "nitty gritty" section in the Blackguard book with Nacho. Talking with him on the phone I learned some particulars about the early 50s' necks that are reflected in these drawings.

The Verneer and maple cap neck drawings...

These will be a nice "C" shape!

ehawley · July 6th, 2008, 12:32 PM

Truss rods....
The rods, as well as the anchors, are made from high carbon drill rod. The adjustment screw is made from 12L14 steel. The screw should strip before the rod itself. That way you can easily change it out if any problems "happen"!
Tap and die...

Standard stuff. The thread on the rod and anchor end is 10-32

Threading the end...

The anchor end is only threaded for about 5/16 of an inch. The adjustment side is threaded about 1 inch.

Tapping the anchor and adjustment screw...

ehawley · July 6th, 2008, 12:33 PM

The anchor....

The anchor is very simple! It is cut with a 120 degree cutter.
First you turn it to the diameter you want. I turn mine to .360 dia. Tap it, and hold it in a collet block...

Set the 120 cutter on center and cut away!!

Turn the block 90 degrees and cut again. You end up with an anchor that looks like this...

Mounting on the rod...

ehawley · July 6th, 2008, 12:34 PM

Ready to be peened...

And here it is peened and finished...

Should do the trick!!

Here is the anchor for the verneer necks. Self explanatory...

ehawley · July 6th, 2008, 01:03 PM

Here is the wood for the body...

One piece swamp ash.
Thanks Dwight

Here is the wood for the verneer (rosewood) and maple capped necks...

Man o man look at that flame!! The wood is .94 thick. Great for the verneer and capped necks!
Thanks again Dwight!! One of these babies will be headed back your way!

ehawley · July 6th, 2008, 01:05 PM

Here is the wood for the broadcaster necks...

Just plain old hardrock maple from Willard Brothers, where I buy most of my wood.

Well...I hope this wets your appetites. Next week will be CNC time for the body. I have to clear some real work out of the way. (ain't that always the case)

As usual all the files, (dxf, dwg, parasolids, pdf) will be posted soon.
Thanks all
Cheers
ED

guitarbuilder · July 6th, 2008, 01:11 PM

Cool Ed! Welcome back for another round. I look forward to it.
Marty

RichardWitt · July 6th, 2008, 01:15 PM

Oh man! Oh man! Here we go again!

This is gonna be fun!!!

thaus · July 6th, 2008, 01:25 PM

Cool!! Funny Ed when you mention this as just 'standard stuff'........not for us 'tool deficient' beings!!

Nick JD · July 6th, 2008, 06:56 PM

Quote:

Originally Posted by ehawley

, very

.

jwells393 · July 6th, 2008, 08:39 PM

Quote:

This will be a multi build thread made popular by ...............

A body .......... a few necks .......... fine, but please don't let this grow into a behemoth thread where it's nearly impossible to find specific steps when the readers are searching for information in the future. When you start a new guitar .......... start a new thread. Just my not so humble opinion.

As you can tell from the above, behemoth threads are not popular with me.

ehawley · July 6th, 2008, 09:26 PM

Quote:

Originally Posted by jwells393

A body .......... a few necks .......... fine, but please don't let this grow into a behemoth thread where it's nearly impossible to find specific steps when the readers are searching for information in the future. When you start a new guitar .......... start a new thread. Just my not so humble opinion.

As you can tell from the above, behemoth threads are not popular with me.

You got it Jack!..

.. Your right, just three necks and a body! I swear!!

Cheers
ED

PS...how do you like the truss anchor? You don't need a milling machine to make it. You can actually file the cross angles in the face of the anchor. They don't really need to be so deep. Just enough to hold the rod from twisting.

Ronkirn · July 6th, 2008, 09:29 PM

Dawggone..... here goes that urge to buy a CNC machine.... Kurching$$

Ron Kirn

GilmourD · July 6th, 2008, 09:33 PM

*drool*

ehawley · July 6th, 2008, 09:37 PM

Quote:

Originally Posted by Ronkirn

Dawggone..... here goes that urge to buy a CNC machine.... Kurching$$

Ron Kirn

Dang!!

I thought you bought one already! I hear the price is really dropping!

K2cnc is the new boy on the scene!
Cheers
ED

PS...HERE is the NAMM show machine...around $11,000. A lot of machine for the money!

Trimmed&Burnin · July 6th, 2008, 09:48 PM

Hi Ed,
I'll be looking forward to this thread. Anybody interested in a CNC might check into Muliticam. I'm looking at a 4x4 myself.

martino · July 6th, 2008, 11:01 PM

Quote:

Originally Posted by Ronkirn

Dawggone..... here goes that urge to buy a CNC machine.... Kurching$$

Ron Kirn

What would a cnc machine large enough to do a neck go for?
I bet the software is what will really kill ya!

Buckocaster51 · July 7th, 2008, 12:07 AM

This should be fun.

I always admire your work.

PeterUK · July 7th, 2008, 03:18 AM

Here we go again. But this time I'll be able to get my project started now that I can walk and I've got rid of crutches!

Peter

Taipan · July 7th, 2008, 11:17 AM

Quote:

Originally Posted by ehawley

Hi all!! Back again for another fun build!

ED - Yahoo ! Looking forward to the New Season of " ED Hawley's CNC Broadcaster Build "

axmaker · July 7th, 2008, 11:19 AM

looks good ed. maybe a 51 p-bass after this one(s)? by that time i'll have some .dxf drawings done.

ehawley · July 7th, 2008, 08:21 PM

Thanks all...It's great to see my friends all here!
Axmaker...got your message...I'll call soon!

OK...here we go!

ehawley · July 7th, 2008, 08:23 PM

The front side of the body and outer shape has been cut!

Here is the sequence of operations...

Fly cut one side using pull-downs. I had to use them because the piece had a slight bow in it. About .095. The piece was 2.05 thick so no matter!

Where would we be without double sided tape?

Since the one side was flat I used the tape to hold down the blank and flycut it to thickness....1.750

I took a test cut to make sure the body was on center to the blank, ( I took the cut at Z0 just to see a slight mark on the wood) and then cut .300 deep. Just to see how it looked

ehawley · July 7th, 2008, 08:24 PM

Man, that's close! about .075 on each side! Just made it!

I then went ahead and cut the pockets. .635 deep for the neck and two pickup cavities, and 1.5 deep for the control cavity.

I then finished the outside, drilled all holes and popped it off.

Front side done!!

More picks!

ehawley · July 7th, 2008, 08:26 PM

There is no wire route under the pickguard because the Broadcasters didn't have one! I'm not sure when they were introduced, but the 51s' started having them.

Now a question! The ferrules on the 50s' guitars were drilled all over the place!!
Should I or shouldn't I??? I don't really like the "missed-matched" ferrules, but to be true..... What do you all think?
The necks will be started tomorrow! Stay tuned!
Thanks all
Cheers
ED

Buckocaster51 · July 7th, 2008, 08:27 PM

Holy Cow!

That looks slick!

ehawley · July 7th, 2008, 08:32 PM

Quote:

Originally Posted by Buckocaster51

Holy Cow!

That looks slick!

Thanks Steve....That was a close call with the width of that baby!...But Dwight came through with one beautiful piece of wood!!
cheers
ED

Arlo · July 7th, 2008, 08:40 PM

Looking good Ed! Nice to see you back in the building mode my friend.

jaydawg · July 7th, 2008, 08:44 PM

That's great Ed!!!!

Looks like a .250 cutter your using to do the bulk of the work? What are you running for a feed and speed with that cutter?

axmaker · July 7th, 2008, 08:46 PM

Quote:

Originally Posted by ehawley

Thanks all...It's great to see my friends all here!
Axmaker...got your message...I'll call soon!

OK...here we go!

got yah, no hurries...
b.t.w that body looks slicker that 3 kittens in a red wagon....

ehawley · July 7th, 2008, 08:46 PM

Thanks Arlo...Nice to see you too! NAMM was great ,huh? Thanks for posting all your pics
Cheers
ED

ehawley · July 7th, 2008, 08:48 PM

HEY!!! Does anyone else see the outline of a long-haired girl in the wood grain at the bridge area??......

bluesjuke · July 7th, 2008, 08:49 PM

Wow, another adventure with Ed!
What part is the profile, just the blackened area or the outside of the blue?

Both would suit me fine.

Buckocaster51 · July 7th, 2008, 08:53 PM

Quote:

Originally Posted by ehawley

HEY!!! Does anyone else see the outline of a long-haired girl in the wood grain at the bridge area??......

shhhhhh...

I don't think she is wearing any clothes!

bluesjuke · July 7th, 2008, 08:53 PM

Quote:

Originally Posted by ehawley

HEY!!! Does anyone else see the outline of a long-haired girl in the wood grain at the bridge area??......

Yeah, I do!
What's her name?

Wait a second! This thread isn't a clandestine Rorschach test is it?

ehawley · July 7th, 2008, 08:59 PM

Quote:

Originally Posted by bluesjuke

Wow, another adventure with Ed!
What part is the profile, just the blackened area or the outside of the blue?

Both would suit me fine.

The profile goes from small to large end. The black inner area is the headstock end, the outside of the blue is the heel end at the transition to the mounting flat.. There is a reason for the "flat" areas at the sides..(about .125). The blackguard book states that the Broadcaster necks had a large rolled area on the sides of the necks.If you look at the top view of the necks, you will see the profiles drawn in dark blue. The dark and cyan picture is a surface view along the neck. I left that flat area to shape when I sand the neck.

ehawley · July 7th, 2008, 09:02 PM

This may help Bluesjuke!

jwells393 · July 7th, 2008, 09:09 PM

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?

ehawley · July 7th, 2008, 09:09 PM

Quote:

Originally Posted by jaydawg

That's great Ed!!!!

Looks like a .250 cutter your using to do the bulk of the work? What are you running for a feed and speed with that cutter?

Yup...your right....feed is 70 IPM and rpm is a slow 5000 RPM. I found that a 4 flute cutter gives me the best finish, but if it is run to fast (like a router) it burns the wood.
Cheers
ED

July 6th, 2008, 12:30 PM	#1 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	CNC Broadcaster build...and then some! Hi all!! Back again for another fun build! Since my last build thread , I have made alot of new friends all around the world! This is what this site is all about!! It can't get any better then here!. I am a member on other sites but this site is my HOME!! The best!! I have learned alot of new "stuff" , and hope that I have contributed some "stuff" also! Now, let us all step out of the "circle" and get on with the build! This will be a multi build thread made popular by sparkely Steve ( aka..Buckocaster). It will be a broadcaster build in the traditional sense, also a 60s' verneer neck complete with pearloid markers and maple cap neck thrown in. (I would like to replace some purchased necks with ones that I built myself). The wood for this build came mostly from my good friend Dwight (aka Superc_1) who I met here. Dwight lives in Arkansas. He aquires some mighty fine wood! He is a great builder also! Some great mandolins and teles! The inspiration for the truss rod anchor came from Jack (aka jwells393) He sent me a picture of a truss rod anchor which I used to make mine for the broadcaster neck. I altered it abit. I'll explain as we go along. I will be winding the pickups for this the same way the broadcasters of the 50s were done. 43 guage wire for both the bridge and neck pickups. Electronics will be the "Blend" control. Tuners will be Kluson single line. I am also machining the jack cup! Should be fun!

July 6th, 2008, 01:15 PM	#9 (permalink)
RichardWitt Tele-Afflicted Join Date: Aug 2006 Location: Australia Age: 34 Posts: 1,229 1 Photos	Oh man! Oh man! Here we go again! This is gonna be fun!!! __________________ "What a perfect solution to a problem that should have never existed in the first place!"

July 6th, 2008, 09:29 PM	#14 (permalink)
Ronkirn VENDOR Friend of Leo's Join Date: May 2003 Location: Jacksonville, FL Age: 62 Posts: 3,525	Dawggone..... here goes that urge to buy a CNC machine.... Kurching$$ Ron Kirn __________________ Few realize that menopause is mentioned in the bible.. It can be found at Matthew 14:92: "And Mary rode Joseph's ass all the way to Egypt ..."

July 6th, 2008, 09:33 PM	#15 (permalink)
GilmourD Tele-Afflicted Join Date: Jul 2003 Location: Nutley, NJ Age: 29 Posts: 1,699	drool __________________ Good deals: Joel Terry Layla Skye Sunny Wally Franky Honey Wolfy

July 6th, 2008, 09:48 PM	#17 (permalink)
Trimmed&Burnin Tele-Holic Join Date: Sep 2007 Location: Bellingham Wa Age: 54 Posts: 832	Cool! Hi Ed, I'll be looking forward to this thread. Anybody interested in a CNC might check into Muliticam. I'm looking at a 4x4 myself. __________________ Keep your lamp Trimmed And Burnin Shannon,

July 6th, 2008, 12:31 PM	#2 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	First, the drawings..... Here is the Broadcaster body drawing... Like the first broadcasters, there is no wire channel route under the pickguard. The treble side of the neck pocket is "straight" which will result in the "shelf" showing under the neck. The Broadcaster neck drawing... The profile... not quite a boat (V) neck, nor a "baseball" bat either, but a nice chunky neck. I made significant changes to this drawing from my originals in my last build! Another fellow that I met through here was David Eichelbaum. He worked on the "nitty gritty" section in the Blackguard book with Nacho. Talking with him on the phone I learned some particulars about the early 50s' necks that are reflected in these drawings. The Verneer and maple cap neck drawings... These will be a nice "C" shape!

July 6th, 2008, 12:32 PM	#3 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Truss rods.... The rods, as well as the anchors, are made from high carbon drill rod. The adjustment screw is made from 12L14 steel. The screw should strip before the rod itself. That way you can easily change it out if any problems "happen"! Tap and die... Standard stuff. The thread on the rod and anchor end is 10-32 Threading the end... The anchor end is only threaded for about 5/16 of an inch. The adjustment side is threaded about 1 inch. Tapping the anchor and adjustment screw...

July 6th, 2008, 12:33 PM	#4 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	The anchor.... The anchor is very simple! It is cut with a 120 degree cutter. First you turn it to the diameter you want. I turn mine to .360 dia. Tap it, and hold it in a collet block... Set the 120 cutter on center and cut away!! Turn the block 90 degrees and cut again. You end up with an anchor that looks like this... Mounting on the rod...

July 6th, 2008, 12:34 PM	#5 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Ready to be peened... And here it is peened and finished... Should do the trick!! Here is the anchor for the verneer necks. Self explanatory...

July 6th, 2008, 01:03 PM	#6 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Here is the wood for the body... One piece swamp ash. Thanks Dwight Here is the wood for the verneer (rosewood) and maple capped necks... Man o man look at that flame!! The wood is .94 thick. Great for the verneer and capped necks! Thanks again Dwight!! One of these babies will be headed back your way!

July 6th, 2008, 01:05 PM	#7 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Here is the wood for the broadcaster necks... Just plain old hardrock maple from Willard Brothers, where I buy most of my wood. Well...I hope this wets your appetites. Next week will be CNC time for the body. I have to clear some real work out of the way. (ain't that always the case) As usual all the files, (dxf, dwg, parasolids, pdf) will be posted soon. Thanks all Cheers ED

July 6th, 2008, 01:11 PM	#8 (permalink)
guitarbuilder Tele-Holic Join Date: Mar 2003 Location: Hemlock, NY Age: 55 Posts: 656	Cool Ed! Welcome back for another round. I look forward to it. Marty

July 6th, 2008, 01:25 PM	#10 (permalink)
thaus Tele-Holic Join Date: Jul 2007 Location: Canada Posts: 520	Cool!! Funny Ed when you mention this as just 'standard stuff'........not for us 'tool deficient' beings!!

July 7th, 2008, 12:07 AM	#19 (permalink)
Buckocaster51 Poster Extraordinaire Join Date: Jan 2005 Location: Iowa USA Age: 57 Posts: 7,331 1 Photos	This should be fun. I always admire your work. __________________ "If you can't say something nice... don't say nothing at all." - Thumper the Rabbit "An awfully lot of time can be wasted waiting for the right time." - Gunsmoke's Doc Adams

July 7th, 2008, 03:18 AM	#20 (permalink)
PeterUK Friend of Leo's Join Date: Mar 2003 Location: . Posts: 2,996	Stop It! Stop It I say! Here we go again. But this time I'll be able to get my project started now that I can walk and I've got rid of crutches! Peter __________________ .

July 7th, 2008, 11:19 AM	#22 (permalink)
axmaker Tele-Meister Join Date: Mar 2008 Location: Oakley, CA Age: 46 Posts: 380 2 Photos	looks good ed. maybe a 51 p-bass after this one(s)? by that time i'll have some .dxf drawings done. __________________ http://www.myspace.com/funkdocman

July 7th, 2008, 08:21 PM	#23 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Thanks all...It's great to see my friends all here! Axmaker...got your message...I'll call soon! OK...here we go!

July 7th, 2008, 08:23 PM	#24 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	The front side of the body and outer shape has been cut! Here is the sequence of operations... Fly cut one side using pull-downs. I had to use them because the piece had a slight bow in it. About .095. The piece was 2.05 thick so no matter! Where would we be without double sided tape? Since the one side was flat I used the tape to hold down the blank and flycut it to thickness....1.750 I took a test cut to make sure the body was on center to the blank, ( I took the cut at Z0 just to see a slight mark on the wood) and then cut .300 deep. Just to see how it looked

July 7th, 2008, 08:24 PM	#25 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Man, that's close! about .075 on each side! Just made it! I then went ahead and cut the pockets. .635 deep for the neck and two pickup cavities, and 1.5 deep for the control cavity. I then finished the outside, drilled all holes and popped it off. Front side done!! More picks!

July 7th, 2008, 08:26 PM	#26 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	There is no wire route under the pickguard because the Broadcasters didn't have one! I'm not sure when they were introduced, but the 51s' started having them. Now a question! The ferrules on the 50s' guitars were drilled all over the place!! Should I or shouldn't I??? I don't really like the "missed-matched" ferrules, but to be true..... What do you all think? The necks will be started tomorrow! Stay tuned! Thanks all Cheers ED

July 7th, 2008, 08:27 PM	#27 (permalink)
Buckocaster51 Poster Extraordinaire Join Date: Jan 2005 Location: Iowa USA Age: 57 Posts: 7,331 1 Photos	Holy Cow! That looks slick! __________________ "If you can't say something nice... don't say nothing at all." - Thumper the Rabbit "An awfully lot of time can be wasted waiting for the right time." - Gunsmoke's Doc Adams

July 7th, 2008, 08:40 PM	#29 (permalink)
Arlo Friend of Leo's Join Date: Jul 2006 Location: Maine [in a van down by the river] Age: 50 Posts: 2,535	Looking good Ed! Nice to see you back in the building mode my friend. __________________ My music? It is free for my friends.

July 7th, 2008, 08:44 PM	#30 (permalink)
jaydawg Tele-Holic Join Date: Jun 2006 Location: York, ME Age: 33 Posts: 717	That's great Ed!!!! Looks like a .250 cutter your using to do the bulk of the work? What are you running for a feed and speed with that cutter? __________________ WWLD (What would Leo Do?)

July 7th, 2008, 08:46 PM	#32 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	Thanks Arlo...Nice to see you too! NAMM was great ,huh? Thanks for posting all your pics Cheers ED

July 7th, 2008, 08:48 PM	#33 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	HEY!!! Does anyone else see the outline of a long-haired girl in the wood grain at the bridge area??......

July 7th, 2008, 08:49 PM	#34 (permalink)
bluesjuke Tele-Holic Join Date: Oct 2007 Location: Bluesland, Texas Age: 53 Posts: 567	Wow, another adventure with Ed! What part is the profile, just the blackened area or the outside of the blue? Both would suit me fine.

July 7th, 2008, 09:02 PM	#38 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 56 Posts: 1,155 48 Photos	This may help Bluesjuke!

July 7th, 2008, 09:09 PM	#39 (permalink)
jwells393 Doctor of Teleocity Join Date: Oct 2003 Location: Albuquerque, USA Age: 65 Posts: 13,965 101 Photos	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? __________________ Jack's Disclaimer: When I say something.... always ask yourself ..... "What the hell does he know?" _ I'm not cool enough to be a Mac person.