CNC Broadcaster build...and then some!

ehawley · July 6th, 2008, 01:30 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, 01:31 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, 01:32 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, 01:33 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, 01:34 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, 02:03 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, 02:05 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, 02:11 PM

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

RichardWitt · July 6th, 2008, 02:15 PM

Oh man! Oh man! Here we go again!

This is gonna be fun!!!

thaus · July 6th, 2008, 02:25 PM

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

Nick JD · July 6th, 2008, 07:56 PM

Quote:

Originally Posted by ehawley

, very

.

jwells393 · July 6th, 2008, 09:39 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, 10:26 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, 10:29 PM

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

Ron Kirn

GilmourD · July 6th, 2008, 10:33 PM

*drool*

ehawley · July 6th, 2008, 10:37 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, 10:48 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 7th, 2008, 12:01 AM

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, 01:07 AM

This should be fun.

I always admire your work.

PeterUK · July 7th, 2008, 04:18 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, 12:17 PM

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, 12:19 PM

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, 09:21 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, 09:23 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

July 6th, 2008, 01:30 PM	#1 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 02:15 PM	#9 (permalink)
RichardWitt Tele-Afflicted Join Date: Aug 2006 Location: Australia Age: 34 Posts: 1,150 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, 10:29 PM	#14 (permalink)
Ronkirn Friend of Leo's Join Date: May 2003 Location: Jacksonville, FL Age: 62 Posts: 2,742	Dawggone..... here goes that urge to buy a CNC machine.... Kurching$$ Ron Kirn __________________ A government big enough to give you everything you want, is strong enough to take everything you have. – Thomas Jefferson Just because you do not take an interest in politics doesn't mean politics won't take an interest in you! -Pericles (430 B.C.)

July 6th, 2008, 10:33 PM	#15 (permalink)
GilmourD Tele-Afflicted Join Date: Jul 2003 Location: Nutley, NJ Age: 29 Posts: 1,568	drool __________________ Good deals: Joel Terry Layla Skye Sunny Wally Franky Honey Wolfy

July 6th, 2008, 10:48 PM	#17 (permalink)
Trimmed&Burnin Tele-Holic Join Date: Sep 2007 Location: Bellingham Wa Age: 54 Posts: 812	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, 01:31 PM	#2 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 01:32 PM	#3 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 01:33 PM	#4 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 01:34 PM	#5 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 02:03 PM	#6 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 02:05 PM	#7 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 02:11 PM	#8 (permalink)
guitarbuilder Tele-Meister Join Date: Mar 2003 Location: Hemlock, NY Age: 54 Posts: 341	Cool Ed! Welcome back for another round. I look forward to it. Marty

July 6th, 2008, 02:25 PM	#10 (permalink)
thaus Tele-Meister Join Date: Jul 2007 Location: Canada Posts: 479	Cool!! Funny Ed when you mention this as just 'standard stuff'........not for us 'tool deficient' beings!!

July 7th, 2008, 01:07 AM	#19 (permalink)
Buckocaster51 Poster Extraordinaire Join Date: Jan 2005 Location: Iowa USA Age: 56 Posts: 5,583 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, 04:18 AM	#20 (permalink)
PeterUK Friend of Leo's Join Date: Mar 2003 Location: . Posts: 2,830	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, 12:19 PM	#22 (permalink)
axmaker Tele-Meister Join Date: Mar 2008 Location: Oakley, CA Age: 46 Posts: 293 2 Photos	looks good ed. maybe a 51 p-bass after this one(s)? by that time i'll have some .dxf drawings done. __________________ It is never too late to be on time....

July 7th, 2008, 09:21 PM	#23 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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, 09:23 PM	#24 (permalink)
ehawley Tele-Afflicted Join Date: Jul 2005 Location: Keyport, New Jersey Age: 55 Posts: 1,014 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