1959 ES-335TD proto build

Discussion in 'Tele Home Depot' started by preeb, May 3, 2011.

  1. telemcCaster

    telemcCaster Tele-Holic

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    I get some help now and then.

    The chop saw is not too handy but gets some use.

    I store my jigs on big shelves and the place is more dusty than I would want. :D
     

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  2. melomanarock

    melomanarock Tele-Holic

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    wow! that's a very cool beast
     
  3. telemcCaster

    telemcCaster Tele-Holic

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    We are going to need some pressed sides if we are going to build one of these.
     

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  4. telemcCaster

    telemcCaster Tele-Holic

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    Let's make some laminated sides. I make them 3 ply with maple-poplar-maple. I first made my sides using a vacuum press and it worked but was not as reliable as I wanted. So I devised this poor man's press. It works just like the one in the factory video but it manual.
     

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  5. telemcCaster

    telemcCaster Tele-Holic

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    I first prepare the veneer with a special treatment then apply glue and load the layup like above then place the cutaway section on and carefully screw it home. It takes a tremendous amount of pressure to get the veneer, the silicone bag and the aluminum slats to bend.
     

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  6. telemcCaster

    telemcCaster Tele-Holic

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    And then...cook the sides at about 350 degrees F for about 3 minutes while the glue hardens.

    Unload and the sides are bent to shape. The glue holds the shape but the heat certainly has an effect at this temp. These sides are very stiff with almost no ability to conform to anything but the shape of the mold.
     

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  7. telemcCaster

    telemcCaster Tele-Holic

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    The side pressing is really a two man operation but I am almost always alone and have to fight it a bit to get the job done. But this is very satisfying to see the finished result when things go right.

    I keep the side laminate on a plywood form while the moisture evaporates and the glue continues to harden.
     

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  8. missinglinkwray

    missinglinkwray Tele-Meister

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    Are they thick enough to get both sides out of one piece?
    Great job, this will probably end up being the most informative chunk of info on archtops and semihollows anywhere online.
     
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  9. telemcCaster

    telemcCaster Tele-Holic

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    This will yield a set of sides with plenty of room for sanding.

    The sides need one flat side with all three plys on the edge flat.

    I used to use a drillpress sander but that proved difficult. I finally took a day and built this rotating sanding plate. It is powered by a 1/2 HP motor. The shaft of the motor has a rubber wheel that spins the edge of the round mdf plate that is covered with plexiglass and coarse grit paper. To turn it on I star the motor and the rubber wheel spins, to engage the flat plate I lean into the motor housing and engage the two. It spins nice and slow. I lean back and it stops. The dust collector catches most of the dust.
     

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    Last edited: May 6, 2011
  10. telemcCaster

    telemcCaster Tele-Holic

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    Sanding the sides.

    Here is a shot of the drive train. I didn't think this up, Mike Doolin did.
     

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  11. telemcCaster

    telemcCaster Tele-Holic

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    ...then I take a look at my bandsaw and see that it is not set up for sawing sides. so I put the high fence on and saw the first slice by starting this way and ending that way.
     

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  12. telemcCaster

    telemcCaster Tele-Holic

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    ...see
     

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  13. telemcCaster

    telemcCaster Tele-Holic

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    The next edge is not perfect so back to the sander...
     

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  14. telemcCaster

    telemcCaster Tele-Holic

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    And the sides are now equal height of about 1.5 inches.

    We are going to need a center block of maple, a tail block of mahogany and a way to connect the sides to them.


    Lets get busy....

    Stay tuned. I am glad you are all staying with Gil and me in this journey.
     

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  15. telemcCaster

    telemcCaster Tele-Holic

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    Thank you for the support.
     
  16. telemcCaster

    telemcCaster Tele-Holic

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    Me too, Gil and I have been keeping it secret for quite a while now. ;)
     
  17. telemcCaster

    telemcCaster Tele-Holic

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    Thanks! And you are welcome.

    I don't consider myself so much talented, as one who perseveres.
     
  18. tangelolemon

    tangelolemon Tele-Meister

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    thanks so much for this. It's really fascinating.
     
  19. Daintree

    Daintree TDPRI Member

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    With talent and perseverance, all things are possible!
     
  20. preeb

    preeb Poster Extraordinaire Vendor Member

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    +1
    BTW, the only way to cut those channels properly is fast.
    Slowing or stopping will result with burning marks because this operation required high RPM for a clean cut.
     
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