Erix Brotherhood Build 2022 = Pack Up The Pieces

erix

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Ok, I'm in!

This might be a tough one to finish on time as we are in the process of packing up shop and moving to a different state. We've got to get our house ready to sell, which means cleaning/painting/packing/showing and I don't know how long I'll have a space to work in here. Compounding matters is a TOUGH housing market in the new city and I don't know if we'll be able to find something that I can work in. We may have to rent for a while with all my stuff packed away. YIKES!

I've made some nice friends here and I will miss them. One of them has gifted me many beautiful pieces of wood over the years. "Too fancy for the stuff I make." he says. So this build is going to be a gift for him and his wife and will be made of drops from wood he has given me.

I'll start with these chunks of walnut. They're 2" thick and dry but they have issues (knots, stains, a split in one end, etc...) I'll have to piece something together to make a body blank of adequate size.
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Still not enough meat - I'm gonna add some paduak strips between them. These will be the "In case you missed it" lines on the multi-part body.
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Squared up the stock and started a multi-day glue-up.
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Next day, ripped the paduak thinner and cut slots in the end with a dado blade.
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Plus signs!
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I used T2 for this.
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Next day ripped new edges on the joined parts and glued on more paduak.
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And the day after that did the same drill with a rip and a dado.
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Scary blade...
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erix

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Time to lay out the body. I had thought I was going to work around one of the splits by wrapping the lower horn around it...
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But it is a nasty split and I fear the horn could break off - nobody wants to see that!
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The crack goes all the way to the glue line...
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Change of plans! Spin the template around and put the crack on the butt side where it will be easier to hide (or feature!) a repair.
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This will help me avoid the light wood on one edge too.
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To the bandsaw!
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After planing to final thickness (1.5" in this case), that crack is nasty!
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I think it'll work out though as this is going to be a full hollow build.
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This is the back side. After hollowing out, this will be .25" thick and the wood is still solid here.
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Lots of holes to drill....
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erix

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One of these boards will be the top. This was a 10' x 7" wide x 7/8" maple board with flame all the way through. I got enough wood for five tops and two necks out of it. Another gift.
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The top, a maple neck blank with some wild bubbly flamey figure - it looks like water - and a pice of some kind of rosewood or bocote or cocobolo or something. All gifts. Thanks Bob!
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If I can't get a neck made in time I will use this neck I made for my last build - still unfretted and unfinished but ready and willing. I didn't get this wood from my neighbor though so.... I'd rather not use it for this build.
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erix

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Thanks! This is kinda fun building with scraps.
Finally got the body roughed out. Have to make a new template AND a new base for router to span the template before finishing this up.
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Time for the top to get some attention. I'll use a thin kerf blade to go as deep as I can on all four sides. Extra tall fence for safety!
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No drama
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Then hand saw the remainder to free the bookmatch lurking inside...
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This process always leave some ugliness but it planes right out.
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Worked on the neck a little too. Cut the blank to rough size (birdseye instead of the flamey water bubbles like I thought I was going to use).
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Ill try to get a lot of figure on the face of the headstock.
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Meanwhile, the top was glued up.
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The major pieces the next day.
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erix

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Here's the top after glue up. There is flame on both sides of the board so I put the sides with the most flame in the center.
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This is the former outside of the board, will be the glued side of the top.
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And after a trip through the planing rig. Happy!
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The other side in the rig. Final dim is .250" with a little low corner but it will be cut off.
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Here's the good side with a naptha bath.
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Really pretty in the middle. The blank areas on either side will be filled with f-holes.
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erix

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Started working on the fretboard. This is zebrawood, a scrap leftover from 1bad914's Zebrabird build. I've never seen it used as a fretboard before - might have to zpoxy it and finish it?
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All done! The little red solder sucker bulb is great for blowing away the wood dust so you can see how deep the saw is. Keeps your face (and lungs) out of the dust!
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Took a skim pass off each side of the neck blank. This birdseye is two-tone!
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This will be the backside. Will be fun to carve this and see what comes out.
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Tonight: truss rod slotting and glue up!
 

erix

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It will be interesting to see how this is going to work. Do you think that thin top will support the bridge.
Yeah, this is total seat o’ the boxers engineering here! But I am taking a lot of clues from maxvintage’s hollow builds, particularly this black one.

This is going to be more living room furniture than player. There will be no electronics, just two f-holes and a wood bridge I’ll make out of something dark and exotic with tusq saddles. I’m planning on some bracing inside, like max’s, along with a bridge plate.

it should sound decent for sitting on the couch and picking off commercial jingles. Being in a controlled environment, I don’t have much worry of it blowing apart but, if it did, I’m only out the time it took to build it!
 

erix

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The truss rod arrived so into the rig and a slot was made.
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Some finaggling at the adjuster nut end with a dremel...
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Ugly but effective!
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Drilled some holes in the waste area of the fingerboard prior to the glue up.
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Into the clamps!
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Trying to decide on position marker materials. Assorted pcs of blue acrylic, fake turquoise, some cocobolo and paduak.
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Paduak wins!
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They will stay on theme...
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cleaning out the radiused fingerboard fret slots so I can locate the holes.
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erix

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It is so hard to see pencil lines on this zebrawood I had to put tape down, trim to fit, and mark the spots for drilling.
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Set up a fence to keep them aligned..
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Going to align the grain in the markers with the grain on the fretboard.
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Glued in with transparent titebond
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And sanded smooth.
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Subtle! Over time these dots will turn a carmel brown and get even more subtle. No idea how long that will be though!
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Wiped with naptha to see what it might look like with some finish on the board.
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Headstock thinned in the rig, radiused on the ROSS, rough cut on the band saw and VERY CAREFULLY routed to shape with a template.
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As it sits for the next two weeks while my every waking moment goes toward getting the house ready to photograph!
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erix

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After two weeks of purging and painting and cleaning I finally had some guitar building time this weekend!
First, I took a perfectly good template and made another template out of it.
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Then smoothed it on the new ROSS
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Then I made a new base for my router out of acrylic so it could span the body.
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Taped on with 4 brads holding it in place - no slippage allowed!
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Routed out with a pattern bit - lots of chips. This is prior to setting final depth of the route.
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Back wall thickness is just under .25".
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erix

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Neck Time - Favorite part of a build!
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First facets in...
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Next ones...

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Mostly there, a shot of naptha to see whats goin' on.
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Tuner holes drilled, more filing and tweaking around the transitions, more naptha.
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Little white corner.
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I'm using vintage style tuners on this so they have stepped holes. .25" on the back side, 11/32" on the front.
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Getting closer!
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I think the birdseye + flame combo is gonna be neat.
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erix

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Time to get serious with the top. Printed out some f-holes, cut 'em out, taped 'em on.
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Marked 'em out like that.
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Flipped it over and did the same thing. I'm gonna thin out the top around the f-holes.
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Taped to the table saw - I do NOT want this to move when I'm freehanding the thinning routes!
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Accomplished w/o drama!
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All I gotta do now is cut out the part with pencil.....
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Getting closer every minute!
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Got a mahogany board from Menards to make the braces out of.
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Almost quartersawn. I'll tilt the blade on my table saw and rip this into a few pieces of brace stock.
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