Guitar Step 1
Guitar Step 1
The first task was to decide what to use for reference material. I chose a book entitled " Building
Your Own Acoustic Guitar: Complete Instructions and Full-Size Plans" by Jonathan Kinkead. I
selected that book after reading about a few others on Amazon but my purchase was rather
impulsive. It walks the reader through building a style of guitar similar to the Martin
OM(orchestra model), which is a smaller guitar with a more body. The book includes lots of
photos and even full scale plans, which are handy, but, while sufficient, lacks information I need.
The next task, which was the source of some consternation, was to select the wood to use for the
body of the guitar. The book recommends specific wood, Sitka Spruce for the top and Rosewood
for the back and sides. I, being the rebel, didn't want to do that, so I chose different wood.
I chose Western Red "Sinker" Cedar for the top (or sound board as it is called) and Claro Walnut
for the sides and back. I purchased both from suppliers on E-bay. The Cedar top is supposed to
create a "warm" sound. I don't really know what that means but that didn't seem like a bad thing
to me. "Sinker" means it came from a Cedar log salvaged from a lake or river bottom and is
therefore, probably pretty old. That idea appealed to me. Claro Walnut is highly figured walnut
from the American Northwest.
I used sand paper, clamped to a flat surface with a long right angle block of wood also clamped
to that surface to complete this job. My thought was that if I ran the edge of each piece of wood
back and forth on the sand paper and along the block of wood, the edge would end up flat.
To clamp the wood pieces together I placed two long and square pieces of wood like a frame, on
my flat surface(a 2X4 foot piece of 3/4" MDL) and held them in place with clamps. Once the
glue was set after a day, it was time to make the sound board and back the proper thickness.
I decided I could get the wood to the proper thickness by hand sanding. My book suggested
2.5mm for the top and 3mm for the bottom. With rubber cement adhesive, I attached a piece of
80 grit sand paper on a flat piece of 8X10 inch plywood onto which I fastened a crude handle. I
placed the wood to be sanded loosely between two long blocks of wood clamped on to my flat
surface. At the ends of the wood, to keep it in place while I pushed and pulled the sanding block,
I clamped a thin piece of wood on one end and aluminum yard stick on the other.
I used the same process to get the side wood to the "proper" thickness.
I used the plans that came with the book to trace half of the body shape onto a piece of cardboard
then transferred that to a small sheet of 1/8 inch thick clear polycarbonate plastic to use as a
template. I used the template to trace the shape of the guitar body on the wood.
Next I trimmed the wood to shape within a 1/4" of the line, with a band saw.
Time to cut a hole in the sound board. I searched online blogs and found how other people
accomplished this. It seemed as if a high speed rotary tool and router bit would give me the best
results. I looked at Dremel tools but after reading reviews I purchased the Black and Decker
RTX-B at about 1/3 the cost of a Dremel.
I overlaid the paper plans on the top cedar sound board and marked the sound hole center by
pressing a tack into the wood. Then I drilled a pilot hole slightly larger than the diameter of the
circle cutter pivot pin. I did the same on a scrap piece of plywood and set up the attachment for
the inside diameter of the rosewood and abalone rosette I purchased also from Amazon for $7.
After carving the inside diameter circle in the scrap wood I checked the depth and diameter and
marked the circle cutter tool brace arm with a permanent marker. Then I cut the outside diameter
and all the material in between it and the inside diameter, checked the fit of the inlay, marked the
brace arm. I did the same for the sound hole diameter on the scrap wood. I now had 3 marks on
the tool for the adjustments. Starting with the inside diameter, then the outside, then removing
the in between wood, then cutting the sound hole, the top was ready to glue in the rosette.
On the back, often there is a decorative strip inlayed to cover the seam. I thought I would inlay a
strip of curly maple cut from the scrap pieces included as packing in order of the back and side
wood. I wanted to put the thin black and white accent prufling strips along each side of the maple
strip. I routed a channel for the maple strip. I decided to make my own wider accent strips from
Mulberry that I cut from my own trees a few years ago. It is a yellowish color.
Inside of an acoustic guitar is bracing for the top and bottom. I believe this is just to make the
thin wood stronger but positioning of the bracing, its thickness and properties of the wood used
can affect the sound of the guitar. I decided to use cedar, maybe this would add to the "warmth of
the sound". I purchased a piece of 5/4 deck planking that looked like it had most of the grain
running longitudinally. Then I followed the bracing shown in the plans to cut the pieces out of
the plank with my table saw, trying to keep the grain longitudinal.
I traced out the bracing pattern on the back side of the top and bottom body pieces. Before gluing
down the bracing I "strategically" removed some material, with the mini-drum sander bit for my
rotary tool to allow the strength to remain but eliminate some of the sound deadening bulk.
Clamping an gluing the bracing on the top required a menagerie of creative clamping methods
and extensions and wedges. The back requires a slightly different menagerie since the bracing
was slightly curved.
A fixture or mold is needed to hold the top, back and sides in place while gluing them together.
The method I chose was to use two sheets of plywood separated by spacers. I used a 3/4", 2 foot
by 4 foot project panel from Home Depot and scrap pieces of 2X4 cut to size for spacers. This
gave me a 24" X 24" mold, which was sliced in half then bolted together again with tab
extensions.
Now to bending the sides. I read lots online about this step, went back and forth on my decision
before I actually did it. I decided, finally, to use a bending fixture made from the scrap pieces cut
out of the mold plywood, which, just happened to be, the shape of the guitar body. I build the
fixture with 2 pieces of the shaped plywood separated by spacers. Then I covered the bending
surface with aluminum flashing. I also added a rounded piece of wood with eye-bolts and wing
nuts, to help hold the side wood against the mold at the deeply curved waist in the body. To
create the steam I built a small square box with a hole in it for steam to enter. Steam was created
using an old coffee pot, with a small piece of copper pipe replacing the glass bubbler, which sat
on a small camp stove.
Once the side to be bent was in the steam box for several minutes and there was an abundance of
steam escaping from its joints, I slowly clamped the wood onto the mold. It bent easily. I was
pleased as well as relieved. The next day I placed the first side in the mold fixture and clamped it
in, then moved on to the next side.
The next step was to trim the side to length and glue them together with the neck block and
bottom block. The neck block was first trimmed to size. It came with the maple neck I
purchased. The bottom block came from a short length of 3/4" maple I purchase at Home Depot.
These four pieces were glued then clamped in the mold. I now had something resembling a
guitar body. The sides needed to be tapered with a gradual curve from the bottom towards the
neck block, which is why it was trimmed earlier. I made a template from 1/8" hard board, with
tapered spacers glued on, to fit around the outside of the body. I put pegs in holes on the inside of
the mold to hold the sides up above the top surface, level with the template at one end and above
the template on the neck end. Then I used a tiny block plane to remove side material to match the
taper.
Step 5: Kerfing Strips, Tail Piece Inlay and Fitting the Neck
3 More Images
Kerfing strips a are long, slotted strips of wood, usually Mahonany or Basswood, that when
glued onto the inside edges of the body sides, add more strength and rigidity. I could have made
my own but I decided to purchase them from Stewart-MacDonald since they were relatively
inexpensive($3.20 a piece for a 15 inch strip, I needed four). First I soaked the strips in water for
several hours to make them more flexible. I then applied a generous bead of Titebond glue and
placed them along the edges of one side of the body with about 1mm protruding. They were held
in place with clothes pins clamped on about every 1/2 inch or so. After the glue dried, I usually
give it a day, I flipped the body and did the same to the other side. The next day I trimmed the
strips that protruded slightly so they were flat and flush with the edges of the sides. I also added
some small vertical bracing strips to the side. Looked pretty good,
I purchased a pre-carved neck from Penta Guitar Works on e-bay. This guy has several styles,
wood selections and scales available. I was impressed with the neck I received. It was a bolt on
neck in Flame Maple (what I always call curly maple), included an routed truss rod channel,
neck mounting block and large peg head suitable for almost any design.
Now I had to figure out how to attach the neck. I found a nice description here:
http://www.liutaiomottola.com/construction/Bolton...
I ordered the exact parts(hex head bolts, washers, and inserts) described, from McMaster-Carr. I
was ready to go, but this step was intimidating also because I needed to be precise. Not my forte.
First, I cut away side panel wood covering the neck block mortise and dry fit the neck. A slight
amount of sanding was required. Then I marked the position for two holes on the tenon of the
neck. Then I marked the neck block, which was now attached to the body to line up with the
holes I marked on the neck. I used a ruler.
I did have to use my small drill press with the base turned backwards to get things to lined up,
and to ensure my holes were square with the neck. This also required some creative clamping
methods. I then drilled clearance holes for the bolts in the neck block and threaded the inserts
into the holes in the neck tenon to about 1/16" below the surface.
I chose a basic Gibson style rod with the adjustment nut meant to be at the peg head, and covered
with a thin plate. This is common with electric guitars. My neck had a well in the peg head
carved for this. The rod came longer than I need, threaded on one end and with one brass
adjustment nut and one cylindrical steel nut. The rod was meant to be cut to length and threaded.
The cylindrical nut was meant to be inlet into the upper end of the neck. Not what I did. I cut the
rod and threaded it with a 10-32 thread and placed the cylindrical nut inside the guitar behind the
neck block. My bracing inside the body was cut with a hole, designed for adjusting the tension
from inside the body.
The tail end of the body where the sides meet creating a seam, is often covered with an inlayed
strip of wood. I decided to use the yellowish Mulberry wood. I used my B&D rotary tool with a
1/8" router bit to carve an inlay channel. I used wooden strips as guides clamped to the body to
get the triangular shape I wanted.
A generous bead of Titebond was squeezed out onto the top to the kerfing and the sound board
was pressed on, trying to keep the centerlines aligned. Creative clamping methods were applied
I used the same process attaching the back, but this is even more of a blind fit and it has more of
a curve than the soundboard. Instead of fussing with clamps I thought I came up with a different
way to clamp the back on. I marked the outline of the body on a piece of 1/4" plywood and cut it
about 1/2" inside of the line. Next I drilled clearance holes for 2-1/2" long drywall screws about
an 2 inches apart all the way around it about an inch outside the line. Then I marked the holes on
the mold surface and drilled smaller holes to drive the screws into. I glued on a piece of guitar
shaped hardboard left over from my side tapering template. After applying glue and lining things
up the best I could I screwed down my improvised clamping board.
First I had to trim the overlap left on the top and back. I decided to cut most off with a band saw
then finish with a flush cut router bit. I ended up borrowing a hand held trim router.
The maple strips had been soaking in water in the bath tub all night and now I was ready to glue
them in. I started with the simpler(no accent stripe) back. Applying a bead of glue to the channel
and I pressed in the maple strip and held it in place with tape, dabbing off excess glue as I went. I
added more tape to areas that looked like they needed it. Once that was done I flipped over the
body and started on the front.
2 More Images
The butt of the neck extended past the body so it needed to be trimmed. I thought I'd make a
decorative cap from 3 contrasting pieces of wood, Mulberry, KOA, and Maple. I cut the neck
butt to length then traced its shape onto the 3 pieces of wood.
Next, I laid out the locations of the tuning pegs on the peg head. I made a paper template from
my plans and checked the distance of the hole locations from the side of the peg head with a
ruler. Then I drilled small pilot holes. The peg head was extra long so I cut it shorter and added a
bit of decorative contour top the top.
After some fine tuning, pun intended, by removing a little wood with sandpaper to make the neck
fit as flush as possible to the body, I removed it and applied some stain. I use Behlen American
Walnut Solar-Lux NGR(non grain raising) stain. I first did a little finish sanding with 240 grit
until I was tired of sanding, the bushed on one coat of stain, leaving the fret board area unstained.
After it dried I sanded again with 240 grit and brushed on another coat. When the 2nd coat dried
I rubbed down the neck with steel wool. I jumped the gun a little in staining the neck now. I had
to re-sand and stain when I created the inlay (next). I also found that when I test fit the nut I had
purchased the neck was a tad too wide. More re-sanding and re-staining.
Once satisfied with the appearance I drilled out the pilot holes to accept the Gotoh Chrome
machine heads. I measured their diameter with micrometers and found a drill bit close to the
same size, which was 3/8" I drilled a test hole first in scrap wood to make sure it would not be to
large. I used a reamer tool to make the tuners fit snuggly into the holes.
First I drew it out on paper then colored in the different areas of the inlay. I liked it so I cut out
each little piece and glued it to some scrap wood that happened to be all similar in thickness.
Once the glue dried I cut out each piece on my band saw, then sanded to the “precise” shape. I
laid out the pieces on a sheet of card stock then glued them in place, making sure to use plenty of
glue where the pieces met.
I cut out a rectangle around the inlay then glued it to a block of wood. My intention was to sand
down the inlay so that all the different pieces were the same thickness. I rubbed the block with
the inlay attached on my large sanding block that was held in a vise.
I now had the inlay shaped like a star, or cross if you prefer, and I traced its outline on the peg
head. Next I used a small chisel to cut, and scrape and finesse the wood out of the peg head
where the inlay would go. After many trial fits and more scraping I finally glued the inlay in
place and slightly above the surface of the peg head. I mixed some graphite powder with
Titebond glue then clamped the inlay in place. I sanded it level with the peg head surface then re-
stained the areas of the peg had that need it. I finished it off with steel wool.
Building the fret board became a time consuming task. I needed to make a few decisions before I
started. Did I want to buy a blank piece of rosewood, cut the slots and radius the surface myself
or purchase a pre-slotted board with a radius? I decided to purchase. By the way the radius on the
surface is supposed to make the guitar a little easier to play, so a flat fret board probably would
have worked. Second decision, did I want to put and edge binding on the board? Yes, I think it
looks better, but makes inserting the fret wire a little more difficult. Third decision, did I want to
attach the fret board to the neck before or after installing the fret wires. I chose after, because I
wanted to use my drill press as a McGuivered fret wire press and I need the board to be flat.
The first thing to do was to cut the fret board to match the neck profile. I laid it on the neck
leaving a little space for the nut, then clamped it to the neck, just eye balling the fret slots for
perpendicularity. I then traced the neck on the back of the board and also the sound hole arc. I
decided to make the bottom of the fret board near the sound hole have a slight arc. I guess that
was a fourth decision. I then cut the fret board slight outside the marks with a bands saw. I used a
small hand plane to clean up the edges.
Next I cut some maple for the side binding out of some scrap that came with my guitar back and
side wood order. It was cut slightly wider than the thickness of the fret board. I then marked its
thickness on the back of the fret board and use a plane to remove additional rosewood to make
room for the binding. I thought of using a trim router to do this but decided to go with caution
and did it using a plane and sandpaper. The maple binding was then glued and clamped to the
fret board, sides first, then the little curved piece at the end of the board near the sound hole. I
had to resort to some more creative clamping. After the glue set I leveled the binding using sand
paper.
I used a ¼” Fortsener bit to make relief for the Abalone fret dots. I tested the fit of the dot in a
drilled out cavity first, then just drilled out each hole with my drill press to a depth that left a bit
of the dot protruding. I drilled then tested, then drilled more, and tested, then more if needed for
each dot. I glued the dots in place with super glue. I used the same method for the side dots
except I used an ordinary drill bit and just estimated the depth I needed, then sanded them flush
once the super glue set.
I made a tool to use in my drill press for a method to press in the fret wire. It was just a ¾” wide
piece of scrap Ash with a ¼” bolt on one side, head cut off of course. I marked a 16 inch radius
curve on the little piece of Ash by using the 16” radius sanding block I purchase from Stewart-
MacDonald Luthier supply. Then I use the drum sanding bit to take off the wood under the line.
For each piece of fret wire I cut the length with a 1/8” to spare on each side of the fret board.
Then with a dremel grinder and small file I removed the barbed portion on the underside of the
wire so that the edges would lay over the side binding. Working on 2 fret slots at I time I use a
small square file to give each slot a slight bevel then tapped the wire down with a hammer and
block of wood just enough to hold it in place. I finished pressing it in with my rigged drill press.
I also used a small piece of aluminum flashing between the wood pressing jig and the fret wire.
Once all the frets were pressed in, I trimmed the edges with wire cutters then filed them flush
with the fret board binding. Since the frets are only held in the slots by the barbs, there is a slight
gap left in the slot. I wicked super glue into the slots using whip tips which I purchased from
Stew-Mac. These handy little tips slide right onto the bottle tip.
I smeared glue on the neck surface and a little on the sound board (top) where the fret board
would lay then clamped down the neck, wiping off the squeezed out glue with a wet paper towel
as I went. I needed to use a C-clamp to attach the fret board to the body, since there is a slight
bend required due to the set back angle of the neck. I hope the strings will clear the frets in this
area.
Like I mentioned earlier, the tension adjustment for the truss rod on my guitar is located on the
peg head....so it needs a cover. I made one from the scrap wood I had around by routing a
shallow channel in the base wood and filling it with contrasting wood. It is a simple shape but a
bit over sized. I had some difficulty making the adjuster nut flush or below the surface so the the
cover would lay flat.
I purchased a premade rosewood bridge, pins and saddle on Amazon. First I laid the bridge on
the sound board with the saddle in place and held a string from the nut to the saddle to check the
action height (distance the string set above the frets)
I first placed a piece of blue painters tape on the sound board where the bridge would sit, and laid
the bridge on top of it. Very carefully I measured the distance from the nut to the edge of the
bridge. I need 25.4 inches (25-3/8 = 25.375). I used a length of braided fishing line strung from
the nut to the bridge pin of the low E and high e strings to find the centering. Then I taped it
down and cut the underneath tape to shape for masking the wood during the lacquer application.
I was ready to apply the finish,
I decided to use Behlen stringed instrument lacquer in aerosol spray cans. It was recommended
to apply at low humidity and temperatures between 60 and 80F. The fumes from this stuff are
hazardous and very volatile. I used a respirator mask and goggles when applying. Since this it
was February when I came to this step I built a small spray booth in my garage from spare
plywood and plastic sheeting in which I placed an electric heater and light. It is also
recommended that 10 coats of lacquer is applied, with light sanding between each coat. I applied
4 coats of Behlen vinyl sealer first with light sanding after the first two coats. I then applied 7
coats of lacquer with light sanding between every 3 coats. I waited a half hour between coats and
a day between every three coats before sanding.
After letting the finish harden for a week I wet sanded the top with 1000 grit paper and water
with a little Murphys Oil soap added to the water the paper soaked in overnight. I only did this to
the top. I preferred an more satin finish for the sides and back so I just lightly rubbed those
surfaces with steel wool. After wiping the water from the top I used Turtle wax rubbing
compound from an auto supply store to polish the finish. I polished by hand with a cotton rag
then again later with a wool buffing bad in a drill. The finish looked OK but, sort of crude. I was
shooting for that Willie Nelson look.
When I laid the bridge over the masking tape I rechecked the distance from the nut, but this time
I considered the compensation. The saddle is set at an angle for compensation and it’s distance
from the nut should be 2mm longer than the scale length(25.4) on the high e string and 6mm on
the low E string.
I made the adjustments measuring from the nut to the saddle, then drilled 3/16 holes in. holes for
the end pins to hold it in place while I glued it down. I carved the shape of the bridge top using a
drill press sanding drum in a small block of wood, and drilled clearance holes for the pins. I used
this with a little padding to help clamp the bridge down during gluing. I straddled the guitar body
with a longer piece of wood and clamped the edges to the guitar body, pressing down on the
bridge block.
Now comes the moment of truth, stringing the guitar and hoping it sounds ok. I almost didn’t
want to do this because I thought maybe it would sound dull. I used Martin medium strings.
After I tuned it an strummed it I was amazed at how it sounded. It had a rich sound(kind of warm
an bright I guess) with lots of sustain. I checked all the stings down to the body, no buzzing. This
guitar may be a little rough and ugly but is sounds beautiful to me.
I am happy.
The photos show my commercially made guitar and my home made guitar
Be sure to vist
http://hubpages.com/_3v4wkz561vqja/entertainment/H...
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44 Discussions
joshholt1999
1 year ago
Hi! I'm in an engineering class where we have a semester long project (18 weeks) to design,
build and turn in a project. I found this idea of building a guitar very unique and would like to try
it. If you could give me any details on how long it might take, things I should do at the same time
to make the building process most efficient, along with things you wish you did with it. Cheers!
2 replies
deluges
1 year ago
This is some seriously amazing work. Favorited for future reference
arvevans
1 year ago
Many of the images do not show. Have the files been removed? Without the pictures this is
pretty much a useless Instructable.
3 replies
francisbradette
2 years ago
hello!
First of all, you realized one of my dream. playing self composed music on a self constructed
guitar. The job you did is wonderful.
First, was the book and some sites sufficient to go through the whole process?
Do you have a source for the wood? If it was to re do, would you buy a go bar deck? or using
clamps was ok? how much did it cost you? how long did you take to do it?
I'm thinking about going to my friends wood shop, is it a good idea or regular home equipement
is fine?
1 reply
TuckerDownunder2893
2 years ago
this project seems like a lot of work and fun. wouldn't mind trying it myself
1 reply
Hamchuc
2 years ago
OMFG...I just started playing guitar on a cheap starter I bought my son when he was 8 and since
I like woodworking I thought it would be such a great idea to build my own acoustic guitar. But
after reading your post, it is obviously beyond my capabilities. I am truly impress with the details
but the opportunity cost is just too great.
1 reply
SherylinRM
2 years ago
I have made guitars [not many and not great] and from what I hear [former recording artist which
means nothing now a days with audacity etc lol]. It sounds just a tad tinny. However, having said
this. Try it again after either one year of it sitting around OR 3 months of daily playing.
It should mellow out by then and have its own unique sounds as every hand made guitar does.
Good work :)
2 replies
jimbojones5678
2 years ago
I had a great time reading this. I am just about to finish up my first electric guitar restoration and
due to the success I have had with that I was nursing ideas of building myself an acoustic next.
After seeing how wonderful yours turned out I can't wait to get started! A question, I have no
clamps (or tools of any sort), can you tell me how many I might need at one time? Just a estimate
if you could. Congratulations and enjoy!
2 replies