Building a Kit Guitar...

Or, be careful what you ask for, as you may GET it!

One of the things that I wanted to do when we moved down here to Vadis, was to start to learn how to make guitars. No small challenge I know. Well, Santa brought me a C.F. Martin guitar kit this year. When finished the guitar will be similar to a Martin D28--East Indian Rosewood back & sides, ebony fingerboard & bridge, white binding with herringbone inlay around top & herringbone strip down the back. You can see from the first picture, below, that what I got does not much resemble a guitar!!! As of the time I am writing this (1/8/2003) I have not even started to attack the construction of the guitar itself. I am, however, waist deep into building workboards, jigs, clamps and special tools that I will need later. (At least thats what all the books are telling me!)

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Here's my new guitar! Seriously, except for the side pieces this is the entire kit as Santa Liz delivered it on Christmas Eve.
The kit instructions recommended that the sides be stored in a fixture to keep them from straightening out, which they are wont to do.
Making a guitar is not just gluing the parts together, (I am learning fast!) when you are starting out it is mostly about building all of the tools, jigs, fixtures and clamping devices that you will need when you actually start to make the guitar. This is a shot of the tool used to work on the fret board. It is a type of shooting board that sits on the work bench and has a lip underneath to keep it from siding around.
This is another of the many fixtures that need to be made prior to any guitar work. This one is called a shooting board. It is used to plane the edges of the top and bottom pieces so they can be joined and glued. The shooting board sits flat on the work bench and you can run a plane along the raised part perpendicular to the boards to be joined. (I'll get some shots of that process later on.)
This is another work board that I will be needing later on. Much of the assembly process will take place on this work board as will the bracing of the back and top plates. The slots will accept several different types of clamps and braces---they are currently under construction!
The slots on the large working/assembly board are intended to accept a range of different clamps and braces. Here, I am working on one of many dowel clamps/braces that are used to assemble and glue the guitar. I am screwing in a 1/4-20 hanging bolt with a wrench and nut.
Here is a complete set of dowel clamps/braces of various heights. The larger ones are used when assembling the sides to the back plate. You can see the wing nuts and washers that tighted the dowel in the workboard slots.
The set of dowel clamps is tored on a little homemade bracket that I mounted on the wall near the window. There are new fixtures and jigs hanging all over the place now!
This is a shot of the large workboard with some of the clamps and braces that will be used. The large dowel braces are along the left edge. The sound hole clamp is mounted in the middle. (It is used to hold the top plate/sound board dow for assembly and brace shaping.) The threaded rod clamps, on the right side, are used during the assemly of the back onto the sides.
I have had a devil of a time finding a marking guage at any of the local hardware stores. (Half the people I asked didn't have a clue what I was talking about!) So, I just knocked one out last night. A length of maple scrap and a piece of walnut, 3/4 inch plywood, a 1/4-20 thumb screw and a piece of aluminum scrap. That plus a little time and a couple of brads and there you have it.
One of the tasks that I will have to accomplish later on is routing the channels for the purfling and bindings. The purfling and binding pieces help to clean up the joint between the sides and the front and back plates. All I had to do was to make a stop for the Dremmel tool that I can adjust to the job at hand. One could, of course, spend a $100 or so to get a binding router. Maybe later...
Here is a shot of some of the workboards stored on the wall, below the window in the workshop. I am going to have to do some rearranging of storage areas so that I can get all of the tools and jigs into reasonable places.

 

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Copyright © 2003 by Richard Johnson