Acoustic Guitar Builder's Production Journal

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Acoustic Guitar Builder's Production Journal

Guitar Production JournalPage 3WHY KEEP A GUITAR JOURNAL?We Guitar Builders need to keep records ofwhat, how, and why we do things. Why did weshape the braces a particular way on this particularbody? Why did we try an amber shellacwashcoat instead of clear with this top? Whatdid we want to accomplish by using an unbalancedbracing thickness on treble and basssides? Did it work?I guarantee, the reasons and ideas will beforgotten quickly as another guitar is beingworked on. (If not, your memory is a whole lotbetter than mine!)With time, you won’t remember all the thingsyou did and your reasons for doing them.Suppose your bright ideas work out perfectly,and you somehow create the Holy Grail guitar?Somebody asks you what you did ... Canyou remember everything? What a bummer ifyou have to take that perfect instrument apartto find out!This journal will work for you if you use it.Three years from now, if you want to repeatthat original Small Jumbo design, you can do itright down to the odd tone bars you snuck in ...if you keep notes!HOW?This document is organized “in blank,” andcan be used in whatever order you want to build.If you work on the neck first, turn to the necksection. Realizing that there are many ways ofbuilding a guitar, I have only included all themain steps; your own intermediate steps canbe added in the space provided.For steps you want to record in your buildingorder that are not in the organized pages,copy and print additional copies of the “Extra”page (provided on page 29) and insert themwhere you need them.KIT GUITAR BUILDERSSteps in italics in the Contents (underlinedin pages) do not apply to most kit guitars,FIRST-TIME BUILDERSWhen I built my first guitar, I was puzzledabout how to do most everything. The secondthrough fifth were better, and it sill improves.Here are some things I wish somebody hadtold me before I started building:1) It isn’t a mistake unless you can’t fix it.2) Do not hurry.3) Think about what the goal of each little stepis: Each stroke of the file, chisel, saw orsandpaper. Every gluing step.4) Test on Scrap.5) Use the appropriate tool, whether you buy,beg, borrow or steal it. Learn (on scrap) touse your tools correctly; the quality of yourwork will directly reflect it. This applies toeverything from clamps to finish sprayers.6) If in doubt about something, stop workingand have some coffee. Where can you findinfo that will help you be sure what to do?How to do it? Be certain before you act.7) Your first guitar, though you will try to makeit perfect, will not be perfect. It will not matchyour hopes. However, you will love it. Youwill also learn from it, and each later projectwill improve. Different procedures will improveat different rates. Skills will improve.Be patient with yourself.8) Before applying glue to anything, dry fit itcompletely to be sure it is correct. Lay outyour clamps, be ready, so the glue won’tbegin to set up before you get the parts secured.9) Test on scrap. Did I mention that?10) Dry fit before gluing. Did I mention that?Remember: It’s all a learning experience.PRESERVE NEW IDEAS ...Make A Note Of ThemAVOID REPEATING MISTAKES ...Make A Note Of ThemREMEMBER IMPORTANT MEASUREMENTS ...Make A Note Of Them!Page 3Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 3


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 4__________________________________________Kits:______________________________________________________________________________________________________________________________Check status of Kit contents____________________________________________________________________________________Check sides for warpage or __________________________________________cupping __________________________________________Use Straightedge____________________________________________________________________________________Acclimate all wood parts to your __________________________________________locale. Set them out for ten days to two__________________________________________weeks.Humidity target: 40-50% RH.__________________________________________TOOLS: Humidifier or DeHumidifier __________________________________________Hygrometer ____________________________________________________________________________________Tools? You can buy tools in stages.Suggested Tool List: __________________________________________http://www.nichebooks.com/ __________________________________________toolsforguitarbuilders.pdf____________________________________________________________________________________Get at least a dozen clamps tostart. __________________________________________TOOLS: Large Cam Clamps __________________________________________Squeeze Clamps (Lg & Sm) __________________________________________Rubber Bands (Very Large)__________________________________________Don’t overspend; chec eBay. ____________________________________________________________________________________Got Supplies?__________________________________________Glues, tapes, wax paper,rags, shop towels ... ____________________________________________________________________________________See:__________________________________________www.stewmac.comwww.lmii.com__________________________________________www.acousticguitarbuilder.com __________________________________________for suggested lists of supplies ____________________________________________________________________________________Page 4Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 5Rim / Sides:Prepare The SidesMeasuring/MarkingTOOLS: Plan or TemplateWhite pencilStraightedgeCuttingTOOLS: Band saw, coping sawBendingTOOLS: Bending iron or FormBending ApparatusorBending Blanket, etc.GlovesFire Extinguisher____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 5


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 6Set up moldTOOLS: Mold Types:External, InternalIf building a Kit, follow directions.(If a Martin kit, click here whilereading this PDF online, for info onmaking an internal mold á laStewart-MacDonald)Make neck and tail blocksTOOLS: TemplateSawBench viseCarpenter’s SquareFile(s)SandpaperCurved Caul for sandingPage 6____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 7Glue neck and tail blocks torimsTOOLS: Wood GlueCam ClampsSqueeze ClampsWax PaperCaulsSet up internal mold (ifnot using external)Click this link while onlinefor infoif not building with aStewmac Kit.Shape Sides -- if not yetdoneTOOLS: TemplateHand PlaneCoping Saw“Microplane”SandpaperFilesGlue kerfed linings ontoBack & Top rimsTOOLS: Glue150 wooden clothespinsRubber Band on each pinRazor Knife or Razor saw____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 7


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 8Page 8__________________________________________BACK PLATES:__________________________________________True Edges of Plates __________________________________________TOOLS: Shooting block __________________________________________w/ 80-100 sandpaper__________________________________________bright light for “candling”(or) __________________________________________jointer ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Join Back plates __________________________________________TOOLS: 3-4 24” bar clamps__________________________________________3-4 Large Cam clampsglue __________________________________________wax paper __________________________________________flat tabletop or board ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Plane to thickness__________________________________________TOOLS: Hand planeor __________________________________________large thickness sander __________________________________________or __________________________________________hand sanding__________________________________________orhand power plane __________________________________________and __________________________________________good thickness gauge__________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 9Cut & shape Back bracesTOOLS: Pattern or templatecoping saw or band sawfiles and sandpaperTo shape radius on gluing edge:Radiused Sanding dishorCaulorBrace Maker toolMark Brace PositionsOn Back PlateTOOLS: Plan or TemplatePencilRule/StraightedgeGlue Back bracesTOOLS: GlueGo-Bar Deck andSanding Dish with Radius(or)GlueCaulandLarge Cam Clamps____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 9


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 10Page 10__________________________________________TOP PLATES:__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________True Edges of PlatesTOOLS: Shooting blockw/ 80-100 sandpaperbright light for “candling”(or)jointerJoin Top platesTOOLS: 3-4 24” bar clamps3-4 Large Cam clampsgluewax paperflat tabletop or boardPlane to thicknessTOOLS: Hand planeorlarge thickness sanderorhand sandingorhand power planeandgood thickness gaugeMeasure and Mark Insideof Top Plates for Braces &soundholeTOOLS: patternstraightedgepencilCopyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 11Rout RosetteTOOLS:-Rosette Materialcircle cutter or markerchisel (or)Drill Press with Circle/Fly CutterGlue RosetteTOOLS:-Rosette materialCA glue or Weld-on if plastic(or)wood glue if woodWax PaperClamps and Caul (or)weighted boardCut Sound HoleTOOLS:-Drill Press w/Circle cutterDremel Tool with Circle Cutter(or)Coping Saw to cut by handSandpaperFunnel to Sand Perfect CircleCut top out of rectangleTOOLS:-Pattern (1/4” oversize)coping saw or band saw____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 11


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 12Page 12Top BracesCut Brace WoodTOOLS:-Band Saw, Table SawRough Shape BracesTOOLS:-sanding dish orBrace Maker toolSandpaperGlue Curved Top BracesTOOLS:-Go Bar Deck andRadiused Sanding Dish(or)caul(or)flat board if gluing flatClamps(or)Vacuum PressGlue Uncurved TopBracesTOOLS:-Go Bar Deck andRadiused Sanding Dish(or)caul(or)flat board if gluing flatClamps(or)Vacuum Press____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 13Lining, Rim Preparation(Lining already glued torims, from page 7)Sand down kerfed lining,TopTOOLS:-Radiused Sanding Dish(or)Sanding Form(or)Freehand sanding (not recommended)Sand down kerfed lining,BackTOOLS:-Same as for Top (above)Notch lining & rim forBack BracesTOOLS:-Clamps and RubberBandsMarking: White or soft Pencil24” straightedgeRazor Saw or Coping sawFileGood amount of Patience____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 13


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 14Page 14BACK:Tap Tune BackTOOLS:-Finger tipExperienced earsFinish BracesTOOLS:-ChiselCurved ChiselSandpaperGlue Back Plate OntoRimsTOOLS:- Glue ... andGo-Bar Deck (or)24 Spool Clamps (or)24 Cam Clamps (or)Edge-Form and Clamps (or)Rubber BandsGlue in vertical sidebracesTOOLS:-Razor sawFile & sandpaperGlueClampsGlue in Optional BracePlate forPotential Sound PortTOOLS:-glueClamps____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 15TOP:Finish Rough shapingTop bracesTOOLS:-SandpaperFilesTap Tuning of Top,more Brace ShapingTOOLS:- FingertipExperienced EarChiselsSandpaperFinal Shaping of BracesTOOLS:-SandpaperFilesNotch lining for TopbracesTOOLS:- Clamps and RubberBandsMarking: White or soft Pencil24” straightedgeRazor Saw or Coping sawFileGood amount of PatienceGlue Top onto rimsTOOLS:- Glue ... andGo-Bar Deck (or)24 Spool Clamps (or)24 Cam Clamps (or)Edge-Form and Clamps (or)Rubber Bands____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 15


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 16Page 16ROUTING & TRIMTrim Off Back & TopOverhangsTOOLS:-- Router (or)Laminate TrimmerandFlush-cut router bitScrape sides flatTOOLS:- Cabinet ScraperSandpaperInstall end graft/butt wedgeTOOLS:- Depending on Rim Wood:Razor Knife, razor saw, Chisels(or)Router With Straight End-cut BitFilesWedge material and patternCA, Wood, or Weld-on glueClamps or Rubber Bands(This entire step can be done beforegluing back or top, but must be donebefore gluing binding)Rout for binding on BackTOOLS:- Router with the right bitsRouter Guide (while online, clickhere for plans to build one thatworks well)____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 17ROUTING The TOP:Rout for purflingon TopTOOLS:- RouterAppropriate BitRouter GuideRout for Bindingon TopTOOLS:- RouterAppropriate BitRouter GuideGlue & tape binding andpurflingTOOLS:- Glue (CA, Weld-on, etc.)Tape (brown is best: fromStewmac or LMI)Untape binding & purflingTOOLS:-Hair Dryer to soften tapeadhesive and prevent tear-out ofgrainSmooth all of bodyTOOLS:-Scraper(s)Sandpaper(s)Sanding BlockTrim out Opening for NeckJointTOOLS:- Razor saw, Razor Knife(or)Dremel with appropriate bitSandpaperFile(s)sssss____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 17


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 18Page 18NECK & FRETBOARD:Glue Neck LaminationsTOOLS:-JointerGlueClampsCut NeckTOOLS:-Band sawJointer or Table sawShape NeckTOOLS:-Template or PatternJig Saw or Band SawDraw knifeFilesSandpaperGlue peghead if separateTOOLS:-ClampsglueJigCut Neck tenon to fit toBody mortiseTOOLS:- TemplatesRouterAppropriate Bits____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 19NECK:Rout Neck for truss rodTOOLS:-RouterAppropriate BitJigMeasure, narrow neck tonut widthTOOLS:-Bandsaw or appropriatesawFilesSandpaperFinish Shaping neckTOOLS:-Draw knifeFilesTemplate or Neck ProfileSandTOOLS:-Sandpaper____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 19


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 20Page 20FRETBOARD:Measure and slot fretboardTOOLS:-Accurate Measuring ToolsSlotting Jig & SawRadius fretboardTOOLS:-Accurate JigSpecialized ToolsFretboard binding? MarkfretboardMeasure, align fretboard &cut edgesTOOLS:- BandsawfilesPrep fretboard or bindingedgeTOOLS:-Shooting BlockGlue Binding (If using)Inlay Side MarkersTOOLS:-DrillSmall bitSide marker materialInlay Front MarkersTOOLS:-Calipers for dots; or patternsfor detailed inlayDrill Press for dots (or)inlay equipment for detailed inlays____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 21NECK / FRETBOARDGlue on peghead veneerTOOLS:-GlueClampsShape and smoothpeghead veneerTOOLS:-FilesSandpaperCoping SawInlay Insignia or LogoTOOLS:-Inlay EquipmentDrill peghead for tunersTOOLS:-Pattern or TemplateCalipersDrill and BitsTunersFret fretboard to bodyTOOLS:-Fret Hammer or PressTang Nippers (if binding)Fret Nippers60º and 90º FileFilesCA glue might be neededGlue Fretboard Binding(File Fret Ends First)TOOLS:-GlueRubber Bands & ClampsDe-burr, Rough FIle FretEdges(If Not Bound)TOOLS:-Small Files, DO NOTHURRY!____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 21


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 22Page 22NECK/FRETBOARDFinish setting neck joint,neck setTOOLS:- FilesAppropriate tools for DovetailorMortise & TenonGlue in truss rodTOOLS:- GlueClampsGlue fretboard to neckTOOLS:-GlueClampsRubber BandsMake nutTOOLS:- FilesSandpaperGlue NutTOOLS:-GlueClampsMake BridgeTOOLS:- TemplateRouterSandpaperFilesDrill or Drill Press____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 23FRETBOARD / BRIDGEFinalize Neck JointTOOLS:-Alignment toolsStraightedgeClampsString & tape for center alignmentFilesAccurate Measuring RuleMeasure bridge position,mark and maskTOOLS:- 24” accurate rulerBlue Masking TapeDrill or Drill PressFinish fretting fretboardTOOLS:-fret hammerRound remaining fret edgesIf Fretboard not boundTOOLS:-Fret files____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 23


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 24Page 24My Finish ChoicesNeck:Back & Sides:Top:__________________________________________NOTE:__________________________________________Tool Tips are Not Given For Finishing Process________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 25Finishing: Preparationof SurfacesNeckBack & SidesTop__________________________________________NOTE:__________________________________________Tool Tips are Not Given For Finishing Process________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 25


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 26Page 26Pore Filling:Pore Filling and FinishNeckPore Filling Back andSidesPore Filling or SealingTop__________________________________________NOTE:__________________________________________Tool Tips are Not Given For Finishing Process________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 27Finish Coats on Body__________________________________________NOTE:__________________________________________Tool Tips are Not Given For Finishing Process________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 27


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsPage 28Page 28Last ThingsGlue Bridge onto BodyTOOLS:- glueClampsAllow finish to Cure For HowLong:See Instructions forFinish MaterialsPolishingInstall tunersTOOLS:-Small WrenchJeweler’s ScrewdriverMake saddleTOOLS:-SandpaperFilesString it upTOOLS:-StringstunerSetup action to likingTOOLS:-Fret FilesRadius Sanding CaulSteel WoolNut and Saddle FilesDONE!____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright © 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar JournalDATE:Guitar:NOTE: Underlined Items Do Not Apply to Most Guitar KitsExtra Page Page _____ 29____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________© 2006 .... Get your own original file of this journal to use for life:Only $9.95 at: http://stores.ebay.com/GuitarBuilderStoreExtra Page _____ Page 29Instruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.


Guitar Production JournalPage 30Information SourcesOne of the neat things about the pursuit of buildingguitars is that the folks at the very top of thefield are accessible. They are friendly and willingto offer guidance and share their knowledge withnewcomers and absolute beginners.Not only can you read all about the building philosophyof renowned guitar makers and repair geniuses,but you can ask them questions on thevarious Internet Discussion Forums.I have even emailed builders of some of the mostbeautiful and desirable handmade instruments, andactually received a personal and fully detailed response!This is a rare and wonderful thing.It’s partly due to the ease of communication viathe internet, but that’s not all. You can email thetop people in other fields and never get a response.Are guitar people kinder and more friendly? Maybe,maybe not. But, they are willing to share their expertise,and that’s something we should all rememberif and when we become accomplished builders.Help those trying to enter the field.Here are a few of the forums, etc., where youcan find builders.www.KitGuitarForum.com -- Building a kit? Thisnew forum has grown fast because it’s the onlyone on the web specifically dedicated to kits.Its “sister site,” www.KitGuitarBuilder.com, is designedto offer instruction to kit builders—not just,“Here’s how I did this, and here’s how I did that...”These are both well worth your time.Acoustic Guitar Magazine Luthiers Corner -- Youcan find some big names, and if you simply askquestions, you can get a lot of great answers.Official Luthier’s Forum -- Again, great info fromaccomplished professionals.Musical Instrument Makers Forum -- Though the“sysop” is stern, she’s knowledgeable and helpful.This is a good forum with a ton of information. Theirprotectionist policy doesn’t let anyone put up a webpage address, but we’ll publish theirs.Searche terms in Google:1. Acoustic Guitar Luthier Forum2. Acoustic Kit GuitarParts, Wood and Tool SourcesThere’s really no need to list these here, exceptfor the few very desirable makers of tools,parts and wood who only offer their wares in theireBay stores. (Because you can search yourself.)If you’ve been around very long in this, you’vealready discovered these lower-priced, customerservice-conscious,active, professional folks.Here is the “search string” for all of the luthierstores on the eBay site. (There are a lot of them.)http://stores.ebay.com/stores/shopstores?query=luthierIf you’re reading this in your computer, just clickthat link and it will take you to the results of thesearch. Otherwise, type it into your browser addressline and click it.ToolsMany builders build their own tools, and throughthe sources already given (forums and ebay stores)you can find a lot that you need.But, how do you know what you need if you arecompletely new at this?As a bonus for buying this document, I offer afree link to a document that normally sells on eBayfor about five dollars. Here it is. It is self-explanatoryand will help you if you are new.http://www.nichebooks.com/toolsforguitarbuilders.pdfIn addition to the tools listed on eBay, you canfind professional tools through these suppliers:Stewart-MacDonald, Inc.http://www.stewmac.comLuthier’s Mercantile International, Inc.http://www.lmii.comHappy Building!Page 30Copyright © 2006 .... Get your own original file of this journal to use for life:Only US$9.95 at: http://stores.ebay.com/GuitarBuilderStoreInstruction Site: http://www.AcousticGuitarBuilder.comDiscussion Site: http://www.KitGuitarForum.comCopyright 2006 by William Cory. All Rights Reserved. No Resale or Redistribution Allowed.Page 30

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