Still wrapping our heads around starting this project, we decided to make a few jigs that will be useful during the build. Unfortunately, we did not take any progress pictures (something I need to get better at during this project). We started off with a simple workboard. The book said to line the outside perimeter with cork, but the plans are for flat board. I think we will add the cork later to help with the curvature of the soundboard and back.
We also build an inside form which will be essential in keeping the sides bent and assembling the box. We traced a template for one half of the soundboard onto a piece of cardboard and then transposed it onto a piece of 3/4” MDF. We rough cut the shape with a jigsaw (no bandsaw in the shop) and then approached the line with a spokeshave, a curved file and sandpaper. Once we were satisfied with the shape, we traced a copy onto another MDF piece and 12 copies onto 1/2” plywood. We roughed them each out, secured them to the MDF and used a template router bit to make every piece an exact replica of the 1st. We then sandwiched the MDF pieces by 6 plywood pieces. I added a hinge and my own spring closure to finish the form.
While we were working on the jigs, we decided it was time to glue-up the neck blanks. This being our first builds, we decided not to buy expensive neck blanks. I had some maple and walnut laying around the shop, so we sandwiched up 3 pieces of 3/4” maple and 2 pieces of 3/8” walnut into neck blanks. We will see if it works…
Thanks for reading,
-- -- Andy, “Those who expect to reap the blessings of liberty must undergo the fatigues of supporting it” - Thomas Paine