Building a Guitar: Part 2 – The Neck

I know that I said in my last post that I was going to use one of the pre-built necks for this guitar, but then I remembered that this guitar is going to use nylon strings. The necks I bought already have truss rods installed, which is really a good thing, but truss rods are most beneficial for steel stringed guitars and not necessary for guitars with nylon strings so I decided to make a neck for this build. But before I started on the neck, I needed to cut the neck pocket in the body.

Because of the way I designed this guitar, I was able to use a scroll saw to cut out the neck pocket close to the lines, then attach the template I 3D printed to get the final shape.

With the neck pocket routed, it was time to begin making the neck. I started the process by grabbing a piece of maple and marking a center line before aligning my template. Unfortunately I didn’t think to take a picture of the process this time, so here’s a few pictures of a neck I did out of poplar.

Like the body, I cut out the neck close to the template lines, then used the router with a pattern bit to get an exact match. I make several passes with the router, taking just a little off with each pass so I don’t risk tearing the wood. I then use a drill press to add the tuner holes based on the same template.

With the basic neck shape done, I proceeded to test fit the piece into the neck pocket on the body. The body was still in very rough shape, but the neck fit perfectly, so I was ready to continue shaping the neck.

There are many different guitar neck designs, and even more ways to shape them, so of course I chose to ignore all of the conventional ways and design my own neck shaping jig.

This jig allows me to use either a rounded or 45 degree angle router bit to shape the rear sides of the neck depending on how aggressive I want the angle to be. For this one, I went with the 45 degree bit. Then, by just flipping the entire jig over, I was able to use a router with the pattern bit set to the proper depth to remove some stock from the head.

So with the neck ready to move on to sanding and assembly, I decided to cut the control cavity into the back of the guitar, then glue the front and back pieces together using every clamp I have.

Then, when the body had adequate time to cure, I did one more test fit before beginning the neck assembly and sanding.

Building a Guitar: Part 1

A couple posts back I talked about how I got into guitar building, and in that same post I said that I would be building another guitar and documenting the process including the neck build. That was only halfway true. I had planned on the next guitar build to include a hand made neck, and I even have the neck started, but then I got an awesome deal on a couple of mostly finished necks so I decided to expedite this next build by using one of them.

This build is the first for the RG5-SC model. The RG5 indicated the overall body style and the SC stands for “Special Cut”. While the overall body shape is the same as the initial RG5 model, this one will be a solid body design instead of the standard semi-hollow design and it will have large weight-saving cutouts.

To begin building the guitar I needed a template. Our local UPS store can print full scale copies, so I saved the file to a flash drive and had them print it out. I could have tiled the file, printed it from my home printer and pieced it together as I’ve done in the past, but the $1.50 cost of having them print it was worth it to save me a little time and effort.

I glued the full size print to 1/2″ MDF board and cut it out with my scroll-saw. Since the outside edge is identical to the standard RG5 design, I cut that edge a little wider, then attached my existing RG5 template to it and used a router with a template bit to give me an exact match. Then, with the template done, I started gluing up my body blanks.

A lot of purists hate the idea of using lumber from the “big-box” stores for building guitars. I understand exactly why the are against it, but our local Menards has select grade Mastercraft lumber that has been surfaced on four sides. By using this, and inspecting it before I buy, I’ve not had any problems. I chose a nice piece of 1″x8″x6′ Poplar, cut it into four 18″ pieces and then glued two sets of two pieces, making sure to use more clamps than necessary:

I like to let the body blanks setup for at least 24 hours, then I use the template to mark the cut lines and use a combination of scroll saw and band saw to rough cut the body shape, making sure to cut just outside the lines. When the rough cuts are done, I then screw the template to the body blanks and use the router with template bit to finish getting the final shape. The template will be right-side-up for the bottom piece and up-side-down for the top to keep the screw holes from being visible after final assembly.

Now that the body is taking shape, the next step will be cutting the neck pocket.