Making Neck Pockets, Screwing Up, Making new Plans

I took advantage of the nice weather a couple weekends ago and had a crack at routing out the neck pocket on the cheapo guitar. Rather than use normaly router bits and a template following kit, I decided to use a template following bit. It has a little bearing on it that rests against the edge of the template which you can see here:


Here is how it follows along the template. You can see that the bearing keeps the router bit from cutting into the template:


After my first crack at, I found that for some reason it didn't cut it completely and there was a little bit of wood still sticking up on the side:


I solved this problem by moving the template over a bit and routing it off. Bad idea. It turns out that it wasn't that the pocket on my template was wrong but that the little stem for the neck was a little too wide. Now my neck pocket is a little too wide for the neck. I am getting kind of ticked about not having my baritone neck, which was what was destined for this neck pocket on anything and this is yet another guitar that won't turn out to be up to snuff so I think I'm just gonna buy a decent Squier Tele and put the baritone neck on that and use the Squier neck for this guy. It kinda sucks that on my second try, I can't make a guitar better than a Squier but there it is. Squier has CNC machines and millions of dollars. If I had that, I'm sure I could make a damned fine guitar.

Anyway, w/ that done w/, I used a template and the same bit to carve a little recess for the control cavity cover. Ended up having to free-hand it a bit and it's not perfect but pretty good. You can see it's a little rough around the edges:


The wood on this guy is a little thicker than a standard tele body so I wanted to make a little recess for the neck plate too. Note to self: make sure that router bit is deep enough that it doesn't destroy your template:

Lots of work down the tubes there. At least it doesn't look so bad I won't be able to fix it up a bit w/ a sander:


After these two mistakes, I decided to call it a day. Sometimes you just gotta leave well enough along. On the brightside, at least I'm not this dumbass fly who got stuck in the carpet tape I use to hold my templates in place. He's dead dow:


Fly: 0
Frank: 1
Luthiery: 2

Second place isn't bad, I guess.

Shaping and Scraping

Ok... My camera is giving me shit so if you're just here for the pics, this is all you get:


So there you have it. That's the body of the cheapo guitar cut to shape and routed. I used pretty much the same method as I did on the baritone body. The only difference is this time I frakked up the glue joint between the two pieces of wood so the top of the thing wasn't quite level so before I started I put some eighty grit paper on my random orbital sander and whirred it across the top and back a few times. Worked like a charm. I used the same template as I used for the baritone body. I like it and just can't think of anything better.

First thing I did was trace the outline on the body and do a rough cut w/ my jigsaw. Last time I tried to use a smooth cutting blade and get as close as possible, which worked OK. This time, I just went ahead and used a fast cutting blade and stayed about a half inch outside of the line. If anything, this method left me w/ less wood to cut away during routing--and it must have saved me fifteen minutes or a half hour w/ the jigsaw. Of course, it could have just been the fact that I have greater and more substantial jigsaw skill now but I really do think this was the better method of doing the rough cut and will continue to use it in the future.

After that, it was a simple matter of routing. I set up my template follower to cut a sixteenth of an inch outside the line and am glad I did. There was a little bit of tear out but, unlike last time, I left some extra wood. Once I was done routing, I just took my trusty random orbital sander and sanded down to the line.

So far, I must say this is head and shoulders above the first one and I think I'm gonna buy a nicer neck than I originally planned. I like the kinda weird streaks on the cheapo alder I'm using and I think this one will be nice enough just to finish w/ a couple or five clear coats. I'm thinking I will get a tele-style neck w/ a maple fingerboard and it will look really simple and classy. Probably go w/ chrome hardware and chrome-covered humbuckers. The only weird thing is it's gonna have about six knobs because of the electronics I'm gonna cram in there.

Gluing Up a Blank

For some reason, I never seem to get around to working on my new project, the cheapo guitar. It is mostly laziness combined w/ the fact that I have a new band started up which takes a great deal of my time. Also, it's fall now so by the time I've relaxed for an hour after work, it's already getting dark and I'm not keen on using power tools w/o proper illumination. However, I did finally get around to gluing up the body blank, which is a relatively simple process.

First thing, the two pieces of alder I bought off the world's most famous auction website had roughly sawed edges that needed to be straightened to be jointed so I could glue them. Originally, I had planned on using a router table for this but, alas, the one I got off that same auction site is the right kind for my router--thought I had a great bargain on it too. Instead, I used a hand plane, which is a fun tool that makes fun, long shavings:


Having never used one of these bad boys in the past, I spent about twenty minutes fixing the mistakes during the first five minutes. Nevertheless, I managed to get it pretty well straight. I checked my progress continually throughout this process w/ a straight edge to make sure I was keeping it real.

Then I put a generous amount of wood glue on there. The brand I chose was Titebond but only because Elmer's (which should work just fine) seemed to commonplace for use in luthiery. Plus, I was pretty damn certain that I wanted it bonded tite-ly.

For some reason, I always think wood glue looks delicious, like a vanilla milkshake:



After I got the two pieces together, it was just a matter of clamping things up and wiping off the excess glue:


Unfortunately, I wiped too much excess glue off and actually manage to suck some out of the joint w/ a paper towel. Just a little but once it was dry, I squeezed some more glue in there to fill up the crack:


Now it is right as rain and feels completely sturdy, like it's a solid piece of wood. Unfortunately, I didn't quite get the two pieces of wood completely even. That is something I'm going to be able to hopefully deal w/ this weekend.

No Hot Luthiery Action

Sorry folks. I've been sidetracked. Took a wonderful vacation w/ my wonderful girlfriend, rented a practice space and took another wonderful vacation w/ my wonderful friends. During the minimal amount of time I've spent working on the three piece neck project, I've realized a) it needed to be expanded to a five piece neck to be wide enough and b) I have no clue how to go about building a guitar neck and am not quite good enough to wing it.

So....

New project! The cheapo guitar.

I have an alder body blank I purchased off eBay for twenty bucks so that's in. Next I'm gonna get a cheapo neck from wherever the hell I can. I have some pickups that I'm taking out of my SG pretty soon that can go in there, some cheap hardware and then I think I'm shove the guts of an old Big Muff or some such thing in there. I will use this guitar to slay peasants.