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Tele Home Depot Building a T-Style guitar? From scratch or from parts. This is the forum for you.

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Old March 9th, 2010, 11:45 PM   #1 (permalink)
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CNC Staple build

Well...Back again for another build. After looking at that olympic white reliced beauty on the music zoo add,(It's gone now!...I'm so sad) I just had to make one similar....You know the one with the black binding front and back, rosewood fingerboard. Yummy!!!
Notice I said "similar"....Color, Fingerboard, and Binding is about the only thing! The body will be Korina left over from the flamed board I bought for my "girl guitars"




There are blemishes on the left over boards so paint is needed to hide them, painting it white is no problem! The neck pickup will be an alnico staple that I designed after the Gibson "Alnico V" staple pickup by Seth Lover and used from 1952 to 56. One of the best pickups I have ever heard! Hands down!!

So...Let's start with the pickup....Here is the design (pardon my reflection...these HD monitors are just too shiney)



The bobbins are CNCed from polycarbonate sheet...



After the top and bottom are machined they are solvent bonded together, cleaned and sanded. and you end up with this...


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Old March 9th, 2010, 11:47 PM   #2 (permalink)
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The Magnets are cut from an Alnico V bar 3/8 by 1/8 by 6" long. I cut them on a diamond saw and surface grind them to .75 long. 6 of them (of course!)...





I then drill a .05 hole in one end .08 down from the edge, on a lathe using a fixture so all are drilled exactly the same...



A brass rectangle piece is cut and drilled on both ends, one hole .05...the other for a 2-56 tap. The brass part is pinned to the magnet using a brass pin.
a .015 tin plated STEEL sheet is CNCed and bent on a fixture for the shield. Gibson shielded pickup wire is soldered in place...

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Old March 9th, 2010, 11:48 PM   #3 (permalink)
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The bobbin is wound with 42 gauge wire...10,000 turns...





9.26 at...



winds!
Here is a picture showing the magnets with the brass rectangular pinned adjustment pieces, 2-56 adjustment screws, springs, and shield in place...

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Old March 9th, 2010, 11:49 PM   #4 (permalink)
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The parts...



The brass rectangular piece is missing...I forgot to take a picture of it!

Finished pickup....





I'll machine a black cover for the one on this guitar!!

The neck is a flamed maple rosewood veneer style neck (same as I made on my surf green guitar)

Neck is roughed out on cnc...

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Old March 9th, 2010, 11:50 PM   #5 (permalink)
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Back is rough shaped....This one is getting a soft v profile...





Neck is flipped, placed on fixtures, and truss rod slot is cut...



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Old March 9th, 2010, 11:51 PM   #6 (permalink)
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Macasser ebony fingerboard is cut for the neck side...





Truss rod is made with square anchor end...



Shaped, filler strip machined and ready to go together....

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Old March 9th, 2010, 11:52 PM   #7 (permalink)
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Truss rod is inserted and filler strip glued in place...









These are the crazy clamps I made for my broadcaster build!! They have many functions when working on necks! They keep everything right on center!
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Old March 10th, 2010, 12:00 AM   #8 (permalink)
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Top of maple is shaped for the veneer...



Veneer fingerboard is glued on...



Here are two necks showing the veneer look. One with veneer finished, the other in process...





This neck will get the "clay dot" look. I have to find out from Gil where he gets his "ivorine"!!.. ;-)
The other (finished) neck is for a Paulownia build which is also going along parallel to this!

Next week will be the body and binding.

Just a note on the pickup design...Gibson used a brass shield and 1 1/8 long by .312 by 1/8 magnets for the alnico v Seth pickup. They also grounded the magnets with a small wire soldered from mag to mag. The springs contacted only the bobbin. I'm using a tin plated steel shield and 3/4 long by 3/8 by 1/8 magnets on mine. The springs on mine contact the shield which ground the mags to the shield. I've tried both the brass and steel shield. I settled on the steel! The shield, because it is magnetic, alters the magnetic field...I think for the better. At least to my untrained ear..;-)

Cheers all!
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Old March 10th, 2010, 01:54 AM   #9 (permalink)
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Awesome, Ed.
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Old March 10th, 2010, 06:23 AM   #10 (permalink)
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Ed...you are the man.... I love the engineering you put into these things. I have all the resources to wind a pickup, I just haven't taken the leap. What wattage iron or gun is needed to solder through the varnish in order to avoid sanding it off and breaking the conductor?
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Old March 10th, 2010, 06:29 AM   #11 (permalink)
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I'm flabbergasted... real pro build.
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Old March 10th, 2010, 06:40 AM   #12 (permalink)
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Fabulous work. How I'd love to have a CNC machine like that (and the skill to use it of course). I shall be eagerly watching this build.
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Old March 10th, 2010, 09:28 AM   #13 (permalink)
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Thanks guys....It's always fun to do these build threads....more fun then just building!
Hey Nick...On March 17th go have a....ummm....I forget what beer you drink...I remember it AIN"T FOSTERS!! Anyhow, have one on me!



Guitarbuilder....It depends on the coating of your wire...Varnish, enamel, and poly all melt around 155C...so no problem with those. Any good iron will blast through that. I have never had a problem. I do use high temp solder though, so grab yourself some of that. I use stuff leftover from my old Singer Sewing Machine Co. days (long time ago...)...some of the new hightemp coatings would be a problem so avoid them if you can. The melt temp of the coatings are usually listed on the wire sites.

Just a quick word on pickups... I love to experiment with a plethora of designs and wierd configurations. I have wound many a humbucker, but still come back to my favorites the single coils!! I have settled on three designs and three different magnet types. Alnico 5, alnico 8, and neodymium (YES! neodymium...but only after I do a secret heat treatment on them)
I will put together a thread for the "just pickup forum" in the future to explain all my experiments and findings. I'll wet your whistle with a few pics...

my group of three...toroidal (neo), fixed rectangle (A8) and my favorite, the staple (A5)
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Old March 10th, 2010, 09:32 AM   #14 (permalink)
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Fixed


neo


Staple...uncovered

Cheers all,
ED
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Old March 10th, 2010, 09:36 AM   #15 (permalink)
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Wow.
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Old March 10th, 2010, 10:01 AM   #16 (permalink)
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Wow.
+one and a half billion...at least...
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Old March 10th, 2010, 10:13 AM   #17 (permalink)
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I think I am suffering from luthier low self esteem now...:-).
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Old March 10th, 2010, 10:15 AM   #18 (permalink)
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Wow.
Ahh ya... +1

Ed - have you ever played with the bobbin height dimensions - I wonder how the height/width of the windings/bobbin change the tone of a pickup?
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Old March 10th, 2010, 10:50 AM   #19 (permalink)
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I would kill a man for a setup like that. I don't need anything quite so large, but to be able to machine pickup parts with such precision would be amazing.
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Old March 10th, 2010, 07:33 PM   #20 (permalink)
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Nice, Ed! Very cool. Thx for sharing.
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Old March 10th, 2010, 08:09 PM   #21 (permalink)
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Hey Nick...On March 17th go have a....ummm....I forget what beer you drink...I remember it AIN"T FOSTERS!! Anyhow, have one on me!
Cheers, Ed - how about I put a couple of drops of green food colouring in an Australian Pale Ale? That'll Irish it up!

Are those neo magnets tubular?
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Old March 11th, 2010, 08:25 AM   #22 (permalink)
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Thanks all....

Yes Nick , they are tubular!







The thing about neos is that they are just to darn STRONG!! The only way to "turn them down" is with heat. But the range in temp that they go from full to zero is VERY small. We have a small electric furnace that is very accurate (+-5c) The trick was to find the time and temp to get the strength you want. I also found a source for the 5-40 fillister head screws...7+ bucks for old stock nickel plated steel bag of 100! I bought 5 bags...enough for my needs!HERE

Pale ale sounds good!! A nice ESB!
Cheers
ED
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Old March 11th, 2010, 08:38 AM   #23 (permalink)
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Body design....


I'm going to have get an anti-glare cover!!! Or just convert the screen image to jpeg and post!

Cut out the pick guard...



1/16 Garolite XX was used. This will get a Lacquer coat (or two!)

Next week the body will be cut...until then
Cheers
ED
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Old March 11th, 2010, 09:41 AM   #24 (permalink)
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Hey ED, don't you have a button on your keyboard that says "Prnt Scrn"? In case you have it you can use it to "copy" what's on your screen and paste it in for example paint. :)
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Old March 11th, 2010, 10:14 AM   #25 (permalink)
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Now THIS is a cool thread ! I'm looking forward to updates...

Thanks Ed !
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Old March 11th, 2010, 10:38 AM   #26 (permalink)
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Just awesome, Ed.

My brother-in-law runs the model shop for an industrial design firm, and I keep forwarding him your posts. I think I will have all of his weekends booked up for at least a year or two!!
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Old March 11th, 2010, 01:44 PM   #27 (permalink)
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Hey ED, don't you have a button on your keyboard that says "Prnt Scrn"? In case you have it you can use it to "copy" what's on your screen and paste it in for example paint. :)
Duhhh...Stupid me! I forgot all about that! Thanks for jogging my memory!!!

I tested it with the pickguard design.
Here you go....



Body...



Thanks again Zatar!

Thanks guys...Robpvd...If they have cnc, go for it! If you need files, let me know!
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Old March 11th, 2010, 11:04 PM   #28 (permalink)
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Respect Mr H!

I need files!!
What CAD and CAM files are you using?
I'm getting ready to start cutting my DIY cnc this weekend.
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Old March 12th, 2010, 12:59 AM   #29 (permalink)
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Respect Mr H!

I need files!!
What CAD and CAM files are you using?
I'm getting ready to start cutting my DIY cnc this weekend.
HOO-AH from an OO-RAH parent! Keep up the good work CptRyg!
I use Mastercam and solidworks for all my designs and CAM, but I can convert to just about anything you need. Just let me know.
Will an attachment reach you ok? I saw your post about the pics not showing.
Cheers
Ed
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Old March 12th, 2010, 01:08 AM   #30 (permalink)
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That's only when I'm on the govt network.
Im learning ACAD10. What's a good compatible CAM for that? Really cheap or Free if possible.
Thanks Ed
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Old March 12th, 2010, 01:22 AM   #31 (permalink)
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That's only when I'm on the govt network.
Im learning ACAD10. What's a good compatible CAM for that? Really cheap or Free if possible.
Thanks Ed
Here is a great site with free stuff HERE...I can send you a zip file with most of my tele files in several different formats. Your posted email in your profile ok?

ED
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Old March 12th, 2010, 01:40 AM   #32 (permalink)
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It's good and thank you!
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Old March 12th, 2010, 11:08 AM   #33 (permalink)
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HOO-AH from an OO-RAH parent! Keep up the good work CptRyg!
I use Mastercam and solidworks for all my designs and CAM, but I can convert to just about anything you need. Just let me know.
Will an attachment reach you ok? I saw your post about the pics not showing.
Cheers
Ed
how about the staple bobbin in .dxf ? i want to try to cut one with a laser. email pm been done sent....
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Old March 16th, 2010, 05:31 PM   #34 (permalink)
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how about the staple bobbin in .dxf ? i want to try to cut one with a laser. email pm been done sent....
got-em Ed thanks! I have a '54 LP custom I'm restoring, and need one of these for the neck pup......
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Old March 18th, 2010, 09:35 PM   #35 (permalink)
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Well, the top of the body is cut. Tomorrow I will make a fixture that will accuratly locate the body to cut the back binding ledge and the furrel cbores.

Korina blank fly cut to 1.75



1/4 cutter set to 1" above top...



Start of cutting...



Finished Cutting top half...

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Old March 18th, 2010, 09:44 PM   #36 (permalink)
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The neck is coming along. Nice fit to the body...



Seems almost a sin to paint this but, like I said in the first post, this blank is made from leftover flamed Korina that I use for some of my other guitars. There are various flaws in the wood that won't look good with a clear finish so, white paint here we come!! I'm going to order the black binding and my "small thin" frets (I'm going to do the "fretless wonder" treatment on this neck) tonight!
Next will be the back side cut.
Thanks all
Cheers
ED
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Old March 18th, 2010, 10:16 PM   #37 (permalink)
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Looks like it is coming along nicely!
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Old March 18th, 2010, 10:21 PM   #38 (permalink)
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My friend, you never cease to amaze me!

Thanks for the inspiration!

Cheers
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Old March 23rd, 2010, 11:03 AM   #39 (permalink)
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Ed, those pickups are very impressive! Keeps up the good work and thank you for sharing.
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Old March 24th, 2010, 12:45 PM   #40 (permalink)
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5 Stars !!!
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