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nosmo's 2012 Challenge Build Thread -- COMPLETED

Discussion in '2012 TDPRI Tele Build Challenge' started by nosmo, Mar 14, 2012.

  1. Midnighttoil

    Midnighttoil Tele-Meister

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    Hi from Cedar Creek, Texas! It seems we are part of the middle-aged-guys-with-Ridgid-sanders-who-make-Telecasters contingent! I'm impressed with your shop construction project. At least you got to start from scratch! I'm working at undoing some work done by the local, er, craftsmen, before I can start mine.

    Oh, and I covet your air conditioner port!
     
  2. nosmo

    nosmo Friend of Leo's

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    doctorrockit - That ROSS is a pretty handy machine. I find myself doing all sorts of stuff with it. Thanks for the shop comments, it is Texas, how could you have a shop without A/C.

    (Of course right now mine is competing with 1000 watts of this
    [​IMG]

    Get too close to that and it gives a whole new meaning to 'redneck'!
     
  3. nosmo

    nosmo Friend of Leo's

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    So....yesterday, before I quit I did some work on the body & neck.

    Here's my all purpose/router/table saw outfeed/workbench in router/planer mode.
    [​IMG]

    The pecan was almost 2" (and slightly cupped) so I had to take off a bit.

    Once that was done I cut it into 2 pieces with my trusty circular saw.
    [​IMG]
    Notice the old blade that tried to burn through it. There's way too much sawdust on the floor for me to be creating that kind of smoke. Changed it out - all good.

    Then I ripped it. I don't have a joiner, but one side was fairly straight. I just trimmed a little off each side.
    [​IMG]

    When I put the 2 pieces together, there was a noticeable gap like the cut was not 90 degrees. This should not have been a problem since I rip with the top side up on 1 piece and the top side down on the other. This usually will compensate for the blade being off a couple degrees. When I checked closer, the boards varied in thickness from one side to the other just over 1/16".

    Who would have thought that when you build an all purpose/router/table saw outfeed/workbench it has to be perfectly flat. Duh!

    Solution - set it up again on the table saw (I know that's flat).
    [​IMG]

    You can see here on the first pass how well my first attempt at a router sled worked.
    [​IMG]

    Once that was done I dressed the edges a little with sandpaper wrapped around one piece as I rubbed the other against it, then swap and do it again.
    [​IMG]

    Clamp it up.
    [​IMG]

    And start to work on the neck.
     
  4. nosmo

    nosmo Friend of Leo's

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    The Brazilian cherry board for the neck was not straight enough to just rip as you can see here.
    [​IMG]

    So I used a bit of MDF that I had cut off earlier and attached it to the board with brads.
    [​IMG]

    Adjust the fence and rip away.
    [​IMG]
    SAFETY WARNING: If you try this I would suggest you use a guide board a little closer to the width of the piece you are trying to square up. I was just trimming about a saw kerf at a time and I was being very careful. I love a table saw, but it can mess up your day real quick.

    OK then - I came out of that with all my digits so lets rip some maple & cherry for the neck.
    [​IMG]

    Resaw some maple.
    [​IMG]

    And get it square & even on the ROSS.
    [​IMG]

    Looks like a pile of.....neck parts.
    [​IMG]

    Glue them up.
    [​IMG]

    And go have a beer.
     
  5. RogerC

    RogerC Poster Extraordinaire

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    I realy want to do a laminated neck on my next one. Love the look.

    As for your router planer-- I've had the same experience, so I've given up on it altogether. I'm probably just going to sell some things and save up to buy a 15" planer... at least that's the plan.
     
  6. Allthesound

    Allthesound Tele-Afflicted

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    Off to a great start keep up the good work man!
     
  7. nosmo

    nosmo Friend of Leo's

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    Well, I took the parts out of the clamps and everything stayed together so today started out well.

    Look - the neck even grew some ears last night.
    [​IMG]

    Sanded it down.
    [​IMG]
    [​IMG]

    Looks pretty flat that way, but from end to end it looked like it had a slight twist. Not really the wood, more like my sanding. Sooooo... I rigged this up to lap both sides.
    [​IMG]
    And just like that its as flat as your 6th grade sweetheart.

    Chopped it at the dumb end and set it aside.
    [​IMG]
     
  8. nosmo

    nosmo Friend of Leo's

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    This is where it starts to get a little nerve-racking. Since this is my first neck, I'm not sure of the sequence of the next steps. I'm sure it can be done several different ways, but this is what I was thinking.

    1:Rout truss rod slot (while the neck is still square)
    2:Mark it, cut it & rout it to shape
    3:Thin out the headstock (and do some fancy secret stuff to it)
    4:Radius the fingerboard
    5:Cut the fret slots
    6:Install the markers
    6 1/2:Drill & Install truss rod
    7:Attach the fingerboard to the neck
    8:Rout fingerboard to shape
    9:Contour the neck
    10:install frets

    What would the pros do?
     
  9. RogerC

    RogerC Poster Extraordinaire

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    *EDIT- Nevermind. I just didn't read closely enough. that's what I get for trying to do this while I'm working hehe
     
  10. nosmo

    nosmo Friend of Leo's

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    The body came out of the clamps too. So here it is being sanded.

    [​IMG]

    Looks pretty flat to me, but I'm standing on that uneven sawdust.
    [​IMG]

    Mark it.
    [​IMG]

    Cut it.
    [​IMG]

    Sand it.
    [​IMG]

    Ready to rout.
    [​IMG]

    About half way through cutting it out on the bandsaw, I realized that there was a specific end I wanted to use at the bridge end of the body and I hadn't even looked at it when I marked it.
    [​IMG]
    I am one lucky SOB. So once again through the virtue of clean living and great Karma, I managed to avert a (minor) snafu.
     
  11. nosmo

    nosmo Friend of Leo's

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    Roger that Roger. It will have a separate (well, not when its finished) fretboard. Yeah, the truss rod - it is 2-way. I hope I don't forget to install it like I almost left it off the list.
     
  12. nosmo

    nosmo Friend of Leo's

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    Hey Roger if you lived closer I'd split the damed planer with you. Boy I miss having one.
     
  13. Muzikp

    Muzikp Friend of Leo's

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    Your neck plan will work and lots of people do it just like that but... I'm no pro, that said I like to cut my fret slots before radiusing and before shaping the neck. Only because I find it easier to cut straight slots in a square, straight, flat piece of wood then to do it on a curved tapered piece. But that's just me. This is a great looking build so far, excellent quality.
     
  14. OpenG Capo4

    OpenG Capo4 Friend of Leo's

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    Sounds like you've got your order of operations mostly right. I usually wait until the fingerboard is on to thin the headstock and do the transition.
     
  15. nosmo

    nosmo Friend of Leo's

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    Muzikp - Good point. I was planning to cut the slots when the fingerboard was still square, but I think I zoned out there for a minute when I made the list. Thanks, I'll just swap steps 4 & 5.

    OpenG - I've seen guys do that here. Actually, I will end up doing the final transition after the fretboard, but I need to do that fancy secret stuff before I put it on.

    I really appreciate the input. Thank you all.

    The scary thing is I'm starting to over think all this. I mean, it's not like I'm building a piano. Oh, wait.......
     
  16. tklaavo

    tklaavo Tele-Holic

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    I feel embarassed when I compare my work with yours, mr. first-timer :D
     
  17. nosmo

    nosmo Friend of Leo's

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    tklaavo - Thank you very much. I used to be a woodworker for a living, but that was quite awhile ago. I'm pretty impressed with the way you are doing your build. I wish your grandmother was around here.

    Stick around the build gets ugly soon.
     
  18. nosmo

    nosmo Friend of Leo's

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    Well - I got all the way to step 2. Had a little hiccup on step 1.

    So here is all the stuff I'll need for the truss rod. It even came with instructions cool.
    [​IMG]
    The piece of pine is for testing the router set up. The BFH actually was used a little later on.

    I set up a router table with a fence and a 1/8" straight bit. Made a few passes with the pine, measure, adjust, more passes, measure, adjust. I set it up so once it was set, the fence would stay and I would just have to run each side of the neck against the fence and I'd have the perfect centered slot. Aint nothing to this, be done in a few minutes.

    See the nice slot?
    [​IMG]
    See how well centered it will be after I run the other edge? Great eh?

    Only problem is I routed it into the wrong side of the neck!:eek:

    I think I taught myself some new words. I used all the bad ones in my vocabulary so I just started making up new ones.

    Alright, calm down, I've seen guys on this forum fix worse things than this. Look over there - there's a strip of neck cherry left over from the center stripe. OK.........this could work.

    Cut a piece off & round the ends a little on the ROSS.
    [​IMG]

    Thin it down and match the grain. Try a test fit.
    [​IMG]

    Glue it before it moves (or I drop it on the floor. If that happens I have to cut another piece 'cause I'll never find it).
    [​IMG]

    Wait for it to dry some - not completely because I want the sawdust to fill any gaps - and cut it kind of flush.
    [​IMG]

    Sand it flush.
    [​IMG]

    And its all gone.
    [​IMG]
    Really!!
    [​IMG]

    Whoa I almost got a fat head there - until I remembered why I had to fix it in the first place. OK that wasted most of the day. Lets see what we can mess up next.
     
  19. flatfive

    flatfive Friend of Leo's

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    You say you haven't built a guitar before!?? :lol:

    I may actually be glad I'm not participating in the beginner category.
     
  20. nosmo

    nosmo Friend of Leo's

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    Oh yeah, I did get the truss rod routed and fit.

    First I marked the neck.
    [​IMG]

    Then I routed the groove.
    [​IMG]

    [​IMG]

    Marked the neck and cut it out.
    [​IMG]

    Routed with the template.
    [​IMG]

    Drilled the adjustment hole and fit the truss rod.
    [​IMG]

    Thats it for the neck for now.
     
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