oooooo k. think this is due for an update. i managed to get a
lot done during the mid-term break and learned some things about what NOT to do :-[. Wiz, unfortunately i did not get to making a spindle sander as i kind of got a bit impatient and the routing went fine for my purposes. i think that i will still get to it in the future though, as i think it is a far more efficient and practical means to finishing a body profile. i'll post a fully detailed thread when i do (probably relatively soon as i'd like to get the second body done sometime soon! this is addictive). anyway - you'll have to excuse the reduced level of photo detail as i was quite strapped for time and wanted to get as much done as possible.
so, routed the outer profile using a top bearing pattern bit at first following the template profile, followed by using a bottom bearing flush trim bit with the bearing following the profile routed by the top bearing bit.
the Ryobi R-150 conked out again - commutator contact of the second rotor also disintegrated. in conclusion i should probably have replaced the brushes at the same time as replacing the rotor :/. anyway, got a triton 2000W router (with loads of cool features) and did this all freehand. this was not without mistakes though:
made a gouge here where the router slipped. patched it up with some sawdust mixed with glue. i will do a touch up here to match the colours and grain patterns so it doesn't stick out so badly. in retrospect here, i should have been more patient and got a plate made up for the triton and built my router table. this will be done by the time i hit the next body!
drilled the string through holes using this little centering jig i made up.
drilled a starting hole about 15mm deep, turned over and slipped onto the pin and then drilled the rest of the way to get a straight hole.
unfortunately (and i realised this too late), the platform of the drill press wasn't 100% level. i tried to get it leveled after turning the platform 90deg to drill the jack hole, but i obviously got it wrong.
this ended up in the ferrules looking like this:
a little off here and there but its no matter as i will be putting in a solid copper or brass (going to test both) tone-bar.
routed the pickup cavities and neck pocket and pilot drilled the bridge mounting holes and the neck mounting holes (a little under the diameter of the screws).
then i routed the jack hole corner 'flat' with a straight edge router guide and drilled the strap button pilots:
then i filled any dents and nicks (along with the knot under the pickguard)
and mouse sanded everything.
Final body weighed in at just under 4lb.
finally, did a rough mock-up:
looking pretty decent i think, all things considered! did a rough set up, setting the intonation, saddle heights and bridge string radius (based on an interpolated value of the conical radius, ended up at 15.5"). still need to set up the nut to get the action a little lower. also a funny thing i noticed, this neck adjusts the relief with clockwise giving more relief (looser truss). which is weird. anyway, she sounds amazing acoustically. can't wait to get some pups in there!
still to come: pickups (with a friend at the moment), finishing (i think i'm going to go with either a partial shellac under polyurethane or a french polish) and a couple of surprises 8)
