A GUITAR UNDER CONSTRUCTION
The following charts list the steps that I will complete during the construction of a guitar that I'm currently making. I usually clear this page twice each year and start with a new guitar for a client who is particularly interested in following the progress of his/her guitar.
The tasks that have been completed are marked as to the date the task was done. Click on the photo links to see pictures of components at various stages of completion. Each picture will open in a new window which can be closed after viewing. In order to get the best view of the pictures make sure the browser window and image are both maximized.
Work takes place under a number of sections during the same time period so you may want to review the whole page each time you come here looking for progress. Also, please bear in mind that I am building one other guitar at the same time, so progress may seem a little slower than it would be if I was making only this one.
This page was cleared and restarted December 23, 2009. Last updated Jan 20, 2010.
Be sure to maximize the images for best viewing.
Materials are as follows:
| Sound board | Master grade Engelmann spruce |
| Back and Sides | Amazonian Rosewood with sap wood stripes |
| Neck | Honduras Mahogany |
| Fret board | African Black Ebony |
| Bridge | Brazilian Rosewood |
| Linings and tail block | Ash |
| Purflings | Holly, Black Veneer |
| Frets | Nickel Silver |
| Rosette | Hand made in Tula, Russia |
| Nut and Saddle | Bleached bone, fully compensated for intonation |
| Tuners | Jorge Graf |
| NECK | Complete | Photos |
| 1. Dimension and true up neck blank and heel stock. | Dec 01 | |
| 2. Cut off head stock to scarf joint angle and true. | Dec 02 | Neck~01 |
| 3. Glue up head stock scarf joint and heel block | Dec 02 | Neck~02 Neck~03 Neck~04 |
| 4. Rout receptor slots for sides | Dec 03 | Neck~05 Neck~06 Neck~07 |
| 5. Rout receptor slots for top | Dec 03 | Neck~08 |
| 6. Rout and glue carbon fiber reinforcement | Dec 04 | Neck~10 Neck~11 Neck~12 |
| 7. Cut heel and foot profiles. | Dec 05 | Neck~09 |
| 8. Rough cut heel and foot side curvature profiles. | Dec 05 | Neck~13 Neck~14 Neck~16 |
| 9 Thickness headstock face plates | Dec 27 | |
| 10. Prepare and glue headstock face plate/veneers | Dec 27 | Neck~17 |
| 11. Cut headstock faceplate nut stop. | Dec 27 | Neck~18 |
| 12. Rough cut neck taper and headstock side tapers. True up headstock tapers | Dec 27 | Neck~19 |
| 13. Rough cut upper headstock design. | Dec 27 | Neck~20 |
| 14. Drill tuner holes. | Dec 27 | Neck~21 |
| 15. Rout headstock slots. | Dec 28 | Neck~22 Neck~23 |
| 16. Roundover top of headstock slots | Dec 28 | Neck~24 Neck~25 |
| 17. Cut ramps and refine headstock shape. | Dec 28 | Neck~26 |
| 18. True up fret board and establish initial thickness. | Dec 29 | |
| 19. Rough cut fret board tapered width and true width to final dimensions. | Dec 29 | |
| 20. Slot fret board | Dec 29 | Neck~27 Neck~28 |
| 21. Taper fret board thickness to final dimensions. | Dec 29 | Neck~29 |
| 22. Drill locator pin holes in fret board at frets 1 and 11. | Dec 29 | |
| 23. Locate fret board on neck, mark and drill neck locator pin holes & install pins. | Dec 29 | Neck~30 |
| 24 Glue fret board to the neck using clamps. | Dec 29 | Neck~31 |
| 25. Trim the sides of the neck to match the fret board. | Dec 29 | Neck~32 |
| 26 Sand a .006" relief curve into the fret board | Dec 29 | Neck~33 Neck~34 Neck~35 |
| 27. True up underside of neck that will mate with the top | Dec 30 | Neck~3 Neck~37 |
| 28. Cut and install frets. | Dec 30 | Neck~38 |
| 29. Trim fret ends, file and bevel. | Dec 30 | Neck~39 Neck~40 Neck~41 |
| 30. Rough shape heel and nut ends of the neck. | Dec 31 | Neck~42 Neck~43 Neck~44 |
| 31. Carve and sand neck to final shape. | Dec 31 | Neck~45 Neck~46 Neck~47 |
| 32. When top ready, dry fit & align neck & top. Mark and cut & finish neck end | Dec 31 | Neck~48 Neck~49 |
| PURFLINGS AND BINDINGS | Complete | Photos |
| 1. Glue up light/dark/light veneer sandwich for back/side purflings | Dec 20 | PB~01 |
| 2. Cut the sandwich into required strips. | Dec 20 | PB~02 PB~03 |
| 3. Glue back centre purfling strips to the back centre inlay. | Dec 20 | Back~01 |
| 4. Glue up white/black veneers for top purflings & cut into strips & bend. | Jan 12 | PB~04 |
| 5. Glue side purfling strips to binding strips and trim. | Jan 13 | PB~05 PB~06 |
| 6. Finalize thickness for binding strips | Jan 13 | PB~07 |
| 7. Bend bindings. | Jan 13 | PB~08 |
| TOP | Complete | Photos |
| 1. Select top, rough thickness and join book matched plates. | Jan 01 | Top~01 Top~02 |
| 2. True surfaces, rout rosette channel and fit the rosette. | Jan 01 | Top~03 Top~04 Top~05 |
| 3. Glue rosette. When dry, level the rosette to top surface. | Jan 01 | Top~06 Top~07 Top~08 |
| 4. Reduce thickness until top is most resonant at or near target | Jan 02 | Top~09 |
| 5. Mark bracing and reinforcement pad positions | Jan 02 | Top~10 |
| 6. Attach upper bout reinforcements. | Jan 02 | Top~11 |
| 7. Cut out sound hole. | Jan 02 | Top~12 |
| 8. Cut out neck interlock slot, dry fit to neck & sides & mark linings perimeter. | Jan 02 | Top~13 Top~14 |
| 9. Glue in dual fan brace lattice using domed solera | Jan 06 | Top~15 Top~16 Top~17 |
| 10. Shape and sand fan braces | Jan 06 | Top~18 |
| 11. Glue in transverse braces and upper bout supports | Jan 06 | Top~19 |
| 12. Shape and sand transverse braces | Jan 06 | Top~20 |
| BACK | Complete | Photos |
| 1. Select back, rough thickness and joint plane centre edges.. | Dec 21 | |
| 2. Join back with center inlay. | Dec 21 | Back~02 |
| 3. Rough cut back to shape and thickness to 2.2 mm. | Dec 21 | Back~03 |
| 4. Attach inner center seam reinforcement and cut passages for back braces. | Jan 10 | Back~04 Back~05 |
| 5. Radius and scallop back braces. | Jan 10 | Back~06 Back~07 |
| 6. Attach back braces. | Jan 10 | Back~08 Back~09 |
| 7. Shape back braces. | Jan 10 | Back~10 Back~11 |
| 8. Prepare label and glue to inner face. | Jan 10 | Back~12 |
| SIDES | Complete | Photos |
| 1. Cut 15mm ash lining strips and thickness to 2.5 mm. | ||
| 2. Bend lining strips | Dec 19 | Sides~01 |
| 3. Glue up lining strips in lamination mold. | Dec 20 | Sides~02 |
| 4. Trim and shape laminated linings. | Dec 23 | Sides~03 Sides~04 Sides~05 |
| 5. True up material for sides and thickness @2.3 mm | Dec 23 | Sides~06 |
| 6. Offcut binding strips if side material is being used for bindings. | N/A | |
| 7. Trim upper edges to accommodate top slope | Dec 24 | |
| 8. Bend sides and trim the ends to fit outside mold. | Dec 24 | Sides~07 Sides~08 Sides~09 |
| 9. Rough trim sides to top profile. | Dec 26 | |
| 10. Rough trim sides to back profile. | Dec 26 | Sides~10 |
| 11. Cut upper bout ends to fit neck recess. | Dec 26 | Sides~14 |
| 12. Attach, plane and shape upright braces each side of the waist | Dec 26 | Sides~11 Sides~12 Sides~13 |
| 13. Prepare and attach tail block | Dec 26 | Sides~15 Sides~16 |
| 14. Attach linings to sides. | Dec 27 | Sides~17 Sides~19 Sides~20 |
| 15. Prepare and fit Side wedges. | Dec 28 | Sides~21 |
| 16. Attach front wedges to sides. | Dec 28 | Sides~22 |
| 17. Prepare & fit rear wedges to dry fit the sides to the neck. | Dec 28 | Sides~23 Sides~24 Sides~25 |
| 18. Rout channel for the tail graft and spot glue temporary graft | Jan 08 | Sides~26 Sides~27 Sides~28 |
| 19. Sand upper linings/sides in hollowed dish mold to match top dome | Jan 08 | Sides~29 |
| 20. Rough cut 2 1/2" binding starter rebates at the neck | Jan 08 |
| BRIDGE | Complete | Photos |
| 1. Cut and true up bridge blank. | Jan 18 | Bridge~01 |
| 2. Drill holes in the tie block area | Jan 18 | Bridge~02 |
| 3. Cut tie block boundary slots | Jan 18 | Bridge~03 Bridge~04 |
| 4. Profile underside of bridge blank to match top dome radius. | Jan 18 | Bridge~05 |
| 5. Rough cut bridge arms to desired height. | Jan 18 | |
| 6. Rout the saddle slot | Jan 18 | |
| 7. Chisel out the valley and round off the front of the bridge. | Jan 18 | Bridge~06 |
| 8. File arms round and bevel arm ends. | Jan 18 | Bridge~07 |
| 9. Angle the top of the tie block | Jan 18 | |
| 10. Fabricate and attach tie block cap.. | Jan 18 | |
| 11. Weigh bridge and refine as needed to reach desired weight range. | Jan 18 | |
| 12. Seal with shellac to prevent bleeding color onto top. | Jan 18 | Bridge~08 |
| 13. Drill bridge locator pin holes at the bottom of the saddle slot. |
| ASSEMBLY | Complete | Photos |
| 1. Align top to neck in assembly form and drill locator dowel holes though the top | Jan 08 | |
| 2. Install temporary dowels, remove from form and check alignment from the top. | Jan 08 | |
| 5. Apply glue to neck surfaces, realign top to neck with locator dowels and clamp. | Jan 08 | Assm~01 |
| 6. Replace top in assembly form, insert sides and mark lining recesses. | Jan 08 | Assm~02 |
| 7. Remove sides and cut recesses in transverse bars | Jan 08 | Assm~03 Assm~04 |
| 9. Mark interlocking recesses in linings for the transverse bars and treble bar. | Jan 08 | |
| 10. Remove sides and cut interlocking recesses into the linings. | Jan 08 | Assm~05 |
| 12. Refine Spanish heel wedges to ensure sides will clamp to the heel. | Jan 08 | |
| 13. Remove sides and apply glue to upper side linings and outer heel gluing surface. | Jan 08 | |
| 15. Clamp sides to top using form clamp system. | Jan 08 | Assm~06 |
| 16. Glue in wedges down leave to dry. | Jan 08 | |
| 17. Remove clamps and level heel and wedges to the sides. Trim excess from top. | Jan 08 | Assm~07 |
| 18. Remove guitar from mold and refine the top/side joint. | Jan 08 | Assm~08 Assm~09 |
| 19. Refine profile of sides to align with back doming. | Jan 10 | Assm~10 |
| 20. Locate and cut tenons in the back braces. | Jan 10 | Assm~11 |
| 21. Locate and cut mortices in the side linings. | Jan 10 | Assm~12 |
| 22. Glue and clamp the back. | Jan 10 | Assm~13 |
| 23. Trim the back waste flush to the sides. | Jan 10 | Assm~14 Assm~15 |
| 24. Rout the top and back purfling/binding rebates | Jan 11 | Assm~16 Assm~17 |
| 25. Hand finish top binding rebates into the neck. | Jan 11 | Assm~18 Assm~19 |
| 26. Hand finish back binding rebates to the heel and tail and miter the center strip ends. | Jan 11 | Assm~20 Assm~21 |
| 27. Fit glue and clamp back purflings with mitered joints to the center strip. | Jan 12 | Assm~22 Assm~23 |
| 28. Fit, glue and clamp top purflings and flush trim. | Jan 12 | Assm~24 |
| 29. Remove the temporary tail graft and replace with the permanent graft. | Jan 13 | Assm~25 |
| 30. Miter the tail graft ends. | Jan 13 | Assm~26 Assm~27 |
| 31. Cut binding ends to fit and miter the purflings to fit tail graft. | Jan 14 | Assm~28 |
| 32. Glue bindings | Jan 14 | Assm~29 Assm~30 |
| 33. Scrape bindings flush to sides, top and back. | Jan 15 | Assm~31 Assm~32 |
| 34. Assemble heel cap components.glue and clamp heel cap. | Jan 15 | Assm~33 Assm~34 |
| 35. Shape heel cap. | Jan 15 | Assm~35 |
| 36. Inspect and correct any small discrepancies. | Jan 15 | Assm~36 Assm~37 |
| 37. Round binding corners and finish sand the entire guitar. | Jan 17 | Assm~38 |
| 38. Apply a shellac sealing coat to the back sides and neck | Jan 17 | Asm~39 Asm~40 Asm~41 |
| 39. Locate bridge and drill locator holes into the top. | Jan 19 | Asm~42 Asm~43 |
| 40.Glue and clamp bridge | Jan 19 | Asm~44 |
| 41. Fabricate nut and saddle. | Jan 20 | |
| 42. Install tuners, attach strings and evaluate the response. Adjust as needed. | Jan 20 | Asm~45 Asm~46 |
| French Polish | Complete |
Photos |
| 1. Seal all purfling lines with cyanoacrylate | ||
| 2. Seal the entire guitar with shellac. | ||
| 3. Fill pores using pumice and alchohol | ||
| 4. Sand filled guitar | ||
| 5. Build up body on all surfaces using french polishing method. | ||
| 6. Level all surfaces with 800 grit wet/dry paper. | ||
| 7. Rebuild the body on all surfaces. | ||
| 8. Level all surfaces a second time if needed. | ||
| 9. Apply glaze coats. | ||
| 10. Rub down with Menernza abrasive polish |