The Electric Guitar

Who’d a thunk it?

I didn’t grow up with music. I vaguely recall being exposed to some in elementary school. Printed music was more bizarre than a foreign language, enough so that I avoided it for decades since.

My son started guitar lessons a couple years ago. Listening to him play, marveling at his ability to learn so easily and a desire to do something special for him, I was inspired to try my hand at making an electric guitar.

Eventually, I hope to have a series of posts that relay the entire process. Before documenting the steps I think it’s prudent to capture some key lessons learned.

If you have a desire to build your own guitar here are some things to consider before going any further:

1) It will be, in almost every case, cheaper to buy than to build. – Unless the guitar you want is custom in some way, as was the one below, by the time you invest in the tools, hardware, electronics and miscellaneous needs you will spend more than it would cost to obtain a decent Chinese knockoff or previously loved guitar.

2) Research, research, research. I read no less than 3 books cover to cover, and would have certainly benefited by reading more. I bought Make Your Own Electric Guitar & Bass by Dennis Waring and David Raymond; Make Your Own Electric Guitar by Melvyn Hiscock and Fretwork Step-by-Step published by Stewart MacDonald. What one book missed the others made up for. Sadly each of them leave something out, leaving you with the challenge of trying to “read between the lines”. There are also a number of helpful forums and sites I found including: www.stewmac.com, www.projectguitar.com, www.tdpri.com, and   www.guitarnuts.com.


Buy the book here!!!

3) Obtain all the hardware before you begin. The most important components are the bridge, tailpiece, fret board and nut since they will play a major role in string height and their relation to the fret board and body of the guitar.

4) Layout  – Make sure you layout every aspect of your guitar before you begin. Key measurements include the scale of course but also you must know in advance the type of bridge so that you can lay out the side profile including the anticipated string height. Fender style guitars have strings that run parallel to the body while most Gibson styled guitars and many others have an angled neck.

5) Jigs n Fixtures – Wherever and whenever possible create jigs and fixtures to ensure accuracy while routing the body, cutting the component shapes are drilling the peg-head, neck or body.

I discovered that my son had created a “trademark” that was showing up on some of his school work, this was the inspiration for the design of his custom guitar. Here is the final result:

Happy Mothers Day – Silhouettes

Here is something really special that you can turn for your wife or mother. A piece to be treasured for years, nake a silhouette of your favorite mom’s children.

For these I began with a digital picture of our 2 children. I had the kids hold a ruler vertically in front of their nose while taking a picture of their profile.

These pictures were printed out on a full sheet of paper. I carefully cut out their profile and used this as a visual template. I prepared two cylinders of dried walnut. Slowly and cautiously I began taking waste material out. Once most waste was removed I began working towards the desired profile. Fine tuning as I went, once I had the basic shape, I simply followed the form until the profile was cut deep enough.

The results were well received!

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Objective of Standardization

This post is titled after a search engine query that brought someone to my site. This query resonated with me because professionally it is a  challenge to help clients learn and understand the value of standardization. This is particularly frustrating personally because to me the concepts of standardization seem simply natural, it just makes sense. So what is the objective of standardization?

Standardization provides a number of potential benefits. Standardization is used to improve quality of a product or service. Standardization provides consistency, valued by your consumers and leading to greater levels of loyalty and retention. Standardization provides a platform for continuous improvement and standardization provides a framework for accountability.

For you, the objective of standardization may vary depending somewhat on context. Are you a sole proprietor turning out dozens of similar bowls in a production shop or are you an artist inspired to create one-of-a kind pieces? Are you a hobbyist trying to make the most efficient use of your limited spare time? Maybe you are one of many on a team of associates working together to grow a business?

At its most fundamental level standardization can be defined as “the best way I/we know how to      (fill in the blank)    .”  It may not be the absolute best way to accomplish a given task. There may be room for improvement, but a standardized way is the best way we know how to…      (fill in the blank)     today.

Think about this definition for a moment. If each day you sanded wood randomly in relation to the grain, some days you would may end up with a nicely finished piece of wood while on other days you would be less than satisfied. Let’s further say that you recognized the poor quality on a given day and changed the your sanding pattern to be in line with the grain. For that day your results improve, right. But if you approach the wood randomly the next day (no standardization) quality falls and work effort increases.

One objective of standardization is solidifying improvements. If we have learned to sand with the grain, improved quality and reduced work, by making this new approach a standard we have forever more locked in the productivity and quality improvements with standardization.

While consumers needs, wants and expectations can vary wildly, two characteristics that all loyal, retained customers share are a desire of value for their money and consistency in service levels and quality. Today you visit a new restaurant, the meal is delicious, the service outstanding the price is low. Next week you return and the food is cold, the service is slow and the price is higher. What are the odds you will try a third time? Standardizations provides the consistency that loyal customers crave.

Over time, we often learn naturally through trial and error how to produce better results. Intrinsically we learn to sand with the grain. We have standardized our approach and established the best way we know how…. today. It’s at this point that we can now leverage the greatest opportunities of having standardization. To quote a great man, Taiichi Ohno, “without standardization, there can be no kaizen (improvement)”

Once we have standardized our approach to a task we now have a platform for continued improvement. If sanding with the grain is better than sanding randomly, what is the next opportunity to improve quality or reduce the effort required? Would a sanding block help or a different brand of sandpaper? Would a progression of finer grit sanding paper help? Maybe it’s a larger variety of grits that we need. Instead of 80 to 120 to 220, would 80 to 100 to 120 to 180 to 220 produce better results faster?

For virtually everyone, the objective of standardization is to aid in producing consistent levels of quality in the most efficient manner known. But if you are part of a larger group, company or organization there are other benefits that should be recognized. Standardization provides a framework for accountability and documented standards provide an excellent tool for training and development.

Accountability is a word often used but seldom applied. In many businesses today, associates are held accountable for “standards” that are often poorly documented or conveyed. By documenting a standard and setting an expectations there is clarity for all and a basis for accountability.

Lastly, in an organization a clearly defined, documented standardized process provides and excellent tool for training new associates or for coaching existing associates to improve their performance.

Tick Tock – A dream realized… in time

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For whatever reason, I have long been fascinated by clocks. Several years ago I began collecting them to my wife’s chagrin. Most are unique but not worth mentioning, cheap and picked up from catalogs in the mail. A few are works of craftsmanship that I’ve chosen to invest in. However, while attending the IWF in Atlanta a few years ago I stumbled across a vendor that provides a kit of templates and jigs to cut the gears necessary to make a wooden movement.

Clocks and wood, how could I not? Purchased from Woodline USA, I began this project nearly a year ago. Between turning, household chores and a few other major projects I slowly but meticulously followed the directions with a few exceptions.

Considering the effort put forth, I could not envision one of these with the cheap plywood provided to cut the gears. I glued up my own custom plywood with 15 layers of exotic veneers I obtained by trolling E-bay late at night.

While the kit provides the templates for the purpose of recreating perfect gears I found there were some imperfections which of course were passed to the final product. However, with some jeweler’s files and determination over several days I was eventually able to adjust all to work.

Frankly, I am too lazy to wind any of our weighted clocks on a regular basis. Being a 12-hour movement I am even less inclined with this one. The first night it ran in our house, I awoke several times through the night to hear the Tick-Tock and fell back asleep with a smile on my face. It’s hard to imagine that so much work can be such fun, but it’s true!

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Economy Vacuum Bags

One of the more exciting additions to my shop in the past couple years has been a vacuum pump. Purchased primarily for use on the lathe I have long wanted to explore alternative uses.

With inspiration from a recent wood magazine I elected to try a desk with a bent laminated top veneered in walnut burl (featured in previous post).

The stumbling block was the price of entry for vacuum bags. Not to be held back and relying on belief in lean thinking it occured to me that a vacuum bag is no more than a large, thick plastic bag. Thinking of possible sources of plastic I quickly landed on shower curtains. I elected to go with the more expensive heavy duty found at any local home supply store.

Laying out the two curtains on top of each other I applied a single bead of vinyl adhesive along the bottom edge clamping the sandwich between 2 by 4’s. After curing overnight I did the same on one side and then the other. After all adhesive was cured I trimed the opening to eliminate the curtain hanger eylets.

The opening is sealed by simply rolling the edges neatly then clamping between 2×4’s. Below you can see a $50 vacuum bag successfully compressing a panel at 20 bars.

Vacuum Bag