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Build project - resonator guitar from recycled bits

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Re: Build project - resonator guitar from recycled bits

Postby zenguitar » Fri Jun 01, 2018 8:43 pm

Not sure I can explain clearly in a forum thread. It's not complex, but the details matter.

Essentially, before raising a new burr you need to remove the old one. You lay the scraper flat on a fine sharpening stone and stone the burr off sideways. Once the burrs are removed on both sides of each edge you then hold the scraper vertically and stone the edges flat and square.

With the scraper flat on the bench you use the burnisher on both sides of each edge hard, about 20 strokes for each edge. If you were to view the scraper close up from the side you would see that the burnishing has changed the edge from flat to slightly concave.

Then you can raise the burr. Put the scraper in a bench vice with one of the concave long edges vertical. With the burnisher horizontal you need to draw it along the concave edge to flatten it out which raises the burr. Then you need to turn the burr which is one stroke with the burnisher at about 30 degrees from horizontal, one on each side. Then flip the scraper over in the vice to raise the burrs on the other edge. When raising and turning the burrs you can start at one end, but I developed the habit of starting from the middle and working out with two half strokes.

Hope that makes some sense :thumbup:

Andy :beamup:
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Re: Build project - resonator guitar from recycled bits

Postby Wonks » Fri Jun 01, 2018 9:24 pm

So basically the opposite to 'wax on, wax off' in The Karate Kid. Here it's 'burr off, burr on'.
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Re: Build project - resonator guitar from recycled bits

Postby zenguitar » Fri Jun 01, 2018 11:38 pm

Yep, you got it mate :)

Andy :beamup:
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Sat Jun 02, 2018 8:04 am

Thanks Andy :thumbup:

Hmmm... I think it’s my burnishing that’s letting me down. Next time I’m in the workshop I’ll get up early and get some practice in..
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Sat Jun 02, 2018 5:34 pm

While I was waiting for glue to dry I had a look at the old Hofner neck. There's a block behind the heel and that will have to come off, and the heel is too small to be useful.

First the block - I wasn't sure what was inside so took it easy and sure enough the truss rod comes all the way to the end. Bit of a bugger as it means I can't remove the whole thing so will need to cut into the guitar top to fit it. Sawed what I could away then used a 'saw rasp' to take it down flat as far as I could. That's a great tool...

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Also squared off the remaining block with a chisel.
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Sat Jun 02, 2018 5:40 pm

Then planed off the small heel so I've got something to glue a new heel to.

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As an aside, the plane in the foreground and the clamp were my father's. He'd had them for a while, and he was 76 when he died 34 years ago so it's nice to see them still in action :)

Here are some maple blocks glued onto the neck that hopefully I'll be able carve into a heel. It's a bit unplayable as it is....

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Re: Build project - resonator guitar from recycled bits

Postby Wonks » Sat Jun 02, 2018 6:05 pm

Have you left enough wood to give enough strength for the truss rod to work properly without it splitting the wood? Presumably Colin thinks it's OK.

I thought he'd have you whipping the fretboard off and fitting a shorter truss rod.
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Sat Jun 02, 2018 7:23 pm

You’re right, he is worried about that, and about cutting into the top. We’re going to have a close look at the whole thing next time, who knows he might dig out another neck. Or hand me some leftover something or other bits and get me to make one from scratch.
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Re: Build project - resonator guitar from recycled bits

Postby Wonks » Sat Jun 02, 2018 8:16 pm

I'm sure you could do it easily.
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 12:06 pm

Well it turns out Col wasn't at all worried about the truss rod/neck joint etc, at least not for long. That look I saw was just his usual thinking frown. So onward.

I did a bit more shaping on the heel:

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and did another mock up:

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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 12:13 pm

Then on to fit the perch pole, which will tenon into the heel and go all the way to the end. In keeping with the recycle/reuse vibe, Colin handed me a dirty old bit of wood he'd bought in a job lot from someone's shed. I cut it to length then cleaned it up. Col said it looks a bit like cherry but there's a pinkish figure going through, not sure exactly what it is. It's very stiff though and thoroughly seasoned.

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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 12:18 pm

Then I need a hole to fit the perch pole through:

Image

Rasping that hole out was a good way to work up a sweat with the weather we've been having.

It's fixed by a single screw at the end. In this case one from Col's old garden fence (he really can't throw anything away).

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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 12:21 pm

If I've measured it right the tailpiece will hide the fencing screw...

...yup :)

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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 12:43 pm

Finally, I need a supporting block on the underside of the top over the perch pole where we are going to screw through the fingerboard. Found an offcut that needed minimal sanding to get the right thickness so epoxy glued it in:

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I'm starting to feel pretty excited now, I'm going to have something that looks like a guitar soon! Just need to:
- shape the perch pole under the cone so it clears the cone
- finish shaping the heel
- rout the top to accept the end of the truss rod and associated wood.
- cut a mortice in the heel to accept the perch pole
- joint and glue the perch pole into the neck
- fit the neck + perch pole to the body

Woo hoo! :bouncy:
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Re: Build project - resonator guitar from recycled bits

Postby blinddrew » Fri Jun 29, 2018 3:24 pm

Just a couple of things to do then... ;)
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 4:05 pm

:) plus a re-fret, replace dot markers, cut a nut, make a bridge. Oh and applying a finish....
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Re: Build project - resonator guitar from recycled bits

Postby Wonks » Fri Jun 29, 2018 4:06 pm

Don't forget learning how to play the resonator!
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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Fri Jun 29, 2018 5:26 pm

Oh bugger forgot all about that!
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Re: Build project - resonator guitar from recycled bits

Postby Martin Walker » Sun Jul 01, 2018 2:34 pm

This is looking really impressive now Adrian! :thumbup: 8-)

Looking forward to hearing it in action soon :D


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Re: Build project - resonator guitar from recycled bits

Postby adrian_k » Sun Jul 29, 2018 9:06 am

Another month has flown by, and we are all that bit closer to our earthly demise. Never mind though, I had another day in the workshop :)

First off, the perch pole I fitted last month needs shaping so that it doesn't foul the cone. I cut a chunk out of the top of the pole and glue it underneath (to retain as much strength in the pole as possible). The resulting shape will no longer fit through the hole I carefully cut last month, so I need to enlarge it by a couple of mil to allow me some wiggle room. I then glue a 2mm patch onto the pole where it crosses the neck block so I have a nice snug fit again.

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