Neck-Thru Build Pics

[Gordon Bellerose]

OK. Got the headstock almost shaped on the new neck for this build.
While I was building this one, I also built 2 more bolt-on necks. One has the headstock shaped and the fret board on, the other needs both.
Here is a shot of the new necks.



And a close-up of the new headstock. NO ugly lines on this one!!

[Art Davila]

looking good.

[Gordon Bellerose]

This is a new jig that I built for neck thru necks.
I will use it with the overhead router to shape the back of the neck.
The whole neck is held solid by the bolts on the headstock end, and by the small screws on the side of the body end.
The dowel across the top is a safety.
There is a neck template under the neck to guide the router.

[Dave Locher]

I am learning so much from this thread. Thank you.

[Gordon Bellerose]

I finished up shaping the back of the neck, and got the pieces glued back together tonight.
There is still some work to do, but it's a bit closer.



A bit more work needed on this side.



Here is a shot of the guitar now.

[URL=http://s398.photobucket.com/user/gordy1013/media/Frozen%20Rose%20Guitars/Neck%20Building/Neck-Thru%20Build/IMG_20150608_201107_zpsattv6bjm.jpg.html]

[Art Davila]

Very nice work. did you use towels to keep it from sliding when you claimed it up or did you just hope for the best?

[Gordon Bellerose]

I used the biscuits like before.

[Gordon Bellerose]

Time to rout the pickup pockets.
I use a template double stick taped to the body, turned upside down, and on the router table.





I have a dust exhaust port in the rear of the router table that keeps the operation nice and clean.
(I keep the router table fence on the rear also)

[Gordon Bellerose]

Routed the pockets 15/16 deep.
Remember the groove I routed in the lower bout? I put a small bolt in it to help show it in the picture.



Here is the body now that I have most of the shaping done. Still some sanding left to do, just to clean the lines up a bit and get rid of any glue that might be on the surface.

Next up is the truss rod and fret board.





And one picture of the rear of the body.

[Art Davila]

Did you remove all of that with the router bit? Or did you remove the bulk with a forstner bit.

[Gordon Bellerose]

I used a forstner bit for a lot of it, and then finished off with the router.

I'm making some maple pickup rings to see how they look. If they don't suit the guitar, I will make some out of walnut and try them. I can always use the maple on another guitar.
I cut the piece a bit large so it isn't so fragile for cutting out the center hole. I drill a bunch of holes, and then use a small saw to cut the piece out. A small rasp and a couple of files finish off the hole.
After that is done, I use a disc sander to shape the outside edges.
Finally, I drill the mounting holes.
It only takes about a half hour each.

I use a metal ring for a template.

[Gordon Bellerose]

Today I drilled the hole from the bridge pickup pocket, to the control cavity.
I use a 1/8 bit first, followed by a 1/4 bit.



Then I drill a hole for the bridge ground wire.
I only use a 1/8 bit for this.



Next, I drilled for the fret board inlay. I'm using plain ol' white MOP dots for this guitar. I'm not sure how good the next 2 pictures are.



And finally, the side marker holes were drilled.

[Art Davila]

I saw a thru neck build I think it was here but maybe not. but the guy pre drilled the wing for the hole to the control cavity and the hole for the bridge ground.

[Gordon Bellerose]

Today I took it easy. Had to go visit my Mother-in-law in the hospital, so not much time to work.

Art.
I find it really easy to drill those channels afterward. I'm not sure, but I think it may be hard to find the exact hole again, once the sides are glued onto the neck.

I have now got the dots inlaid, and smoothed out. I use a file to start, and finish up with sandpaper, and finally the radius sanding block, with 220 grit to clean up.



The fret slots need to be cleaned up to get ready for frets. I use the hand saw with a depth stop for that job.

[Art Davila]

Is that a stu mac saw and depth stop? Or did you find it elsewhere? I have to get one, but have yet to buy it.

[Gordon Bellerose]

Is that a stu mac saw and depth stop? Or did you find it elsewhere? I have to get one, but have yet to buy it.

Yep. Good old Stewmac. I have spent A LOT of money there the last number of years.
It works very well.

[Gordon Bellerose]

Brought out the fret bender tonight also.
I have 2 fret boards to install frets on.



Pressed them in.



Trimmed the ends and here they are. I will file the ends a bit more before gluing them onto their necks.
The one on the left is the one for the neck-thru.

[Gordon Bellerose]

I've got the body all sanded out, and the first coat of grain filler is now on.
I'm using epoxy to fill this guitar, and you can now start to see the colors of the wood.
Tomorrow I will sand back, and apply a second coat.
I decided to fill the body before gluing the fingerboard on.

[Gordon Bellerose]

I now have 3 coats of epoxy on this guitar.
The first two, were applied relatively thick, squeegeed off, and then sanded back almost to the wood.
The last one was applied as thin as I could get it, and will only be scratched with some scotchguard, just to give it a surface that will accept finish.







The next step will be to install the truss rod, and glue the fret board on.

[Art Davila]

.Why do you use three coats of epoxy is that for pore filling