My tele (esquire) build is officially underway...

  • Thread starter Thread starter ratter
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yngzaklynch":1zzlqstq said:
Damn thats some nice flamed maple on that scrap heap :cry:

Man, I've got flamed maple coming out my ass. I'm going to make a flamed maple treehouse for the kids. :lol: :LOL:

Seriously though, the two places I've gone to, to get wood, they both had piles of it. One board is about 10" wide, 10' long, and 1.5" thick - $20. I should be building LP's, not Teles...
 
And we roll on...

A three-piece blank glued up, and another one, two-piece...



Something tells me I might need two before it's all said and done. I don't know why I think that. :D



The planing setup to get the boards to the correct thickness:



The blank gets planed to thickness:



Chopped down a bit.



A template is made by gluing a blueprint to some MDF:



Then rough-cut on the bandsaw:



And sanded to the line on the belt/spindle sander:

 
At this point I realize, hey, I already made this mf'ing template! :doh: :doh:

The template gets attached to the blank:



Then let's try and kill a $90 chinese bandsaw:



It made it through...damn...



Then back to the sander and sand the ever-loving shit out of it...all the way down to the line. The $90 chinese bandsaw leaves a lot to be sanded...



Next it goes to the router to clean up the outside shape....
 
* velcro-fly *":q2e9enn3 said:
ratter":q2e9enn3 said:
Seriously though, the two places I've gone to, to get wood, they both had piles of it. One board is about 10" wide, 10' long, and 1.5" thick - $20. I should be building LP's, not Teles...


Ratter -

Looks awesome :rock:

Now, you need to check out this dudes weblog of his chambered Les Paul builds.....just sick :scared:

http://www.ahandkerchiefsandwich.com/A_ ... hiery.html

Sweet...I saw his neck build months ago and learned a lot from it - I didn't realize he was doing LPs too... :thumbsup:
 
Looks like you're really getting this done and done right. That looks like it's gonna be a smoking guitar!!!!!!!!
 
The outside is routed and edges rounded over (a little softer than vintage spec...I'll probably cut out the other one with the harder vintage roundover and pick which I like better)...next step will be all the interior stuff. Neck pocket routing, pickup routing, control routing, and bridge mounting holes. Need to make templates for all the above.

The plan is a solid color finish (black? white? gold?), white pickguard, standard tele bridge and bridge pickup, no neck pickup. Esquire style. But that's not necessarily set in stone.

And the tru-oil is starting to build up a little gloss/tint on the neck...

IMG_3996.jpg


IMG_3997.jpg
 
Working some more on it today. I made a template for the interior and neck pocket routing.

Lesson learned the hard way: after painstakingly making your templates, use them to cut out a 2nd, 'working' template and store the first one away as a 'master' for when you INEVITABLY destroy the working one. :doh: :doh:

Template is made (shown is the master, on 1/4" because it's easier to do the first time, then I cut it onto 3/4" mdf for a more stable 'working' template):



So, the template screw holes are in the same location as the ones on the body cutout template and it gets attached to the body and I outline the cuts with pencil:



Take it to the drill press and use a forstner bit to hog out some material. Drilling is faster and saves wear and tear on expensive router bits:



Then the template is reattached and the routing is done, like the body shape was, with a "pattern-following" bit. The bit has a ball bearing that rides on the template so that the router follows the template and stays where you want it to:



Those routes aren't all full-depth yet. I needed to come in here and double-check the specs before finishing them off...

Also in the works is a 2nd, 2-piece ash body that will have a harder, vintage-style roundover. It still needs interior routing. And after reading about the original Broadcaster prototypes - which were thin pine bodies with maple necks with no truss rods - I grabbed an old board from behind the shed and have two thinner body blanks glued up to be routed. This is 130+ year old pine from the barn I had torn down - it was probably cut from on or near my property, which is also pretty cool. To think I gave away a barn's worth of this stuff a couple years ago... :doh: :doh: :doh: :doh: :doh: :doh: :doh: :doh:

Complete with bug holes, cracks, square nail holes....and light as a freaking feather. I'd be surprised if the finished body weighs more than three pounds. Doesn't quite look like the pine you get from Home Depot! I'm going to have to ask around and find some more since I gave all mine away...



Next up, finish routing this body and the other three (things go pretty quick once the templates are dialed in, copied, etc.), start prepping them for finishing, and slap together a truss-less neck.
 
yngzaklynch":1jzxzvdm said:
Awesome!! Gettin close to hardware time!!

Yep, gettin' there! Might be several weeks away if I end up doing a nitro finish, but I haven't decided yet...........
 
I haven't read the whole thread, but everything looks so cool. What kind of pickups are you going to use? The only reason I ask is that I bought a MIM Tele last week and am thinking hard about replacing the stock pickups in it. I've been thinking about those Fralin Blues whatever they're called.

I had a Tele built for me back in the day and the guy who built it used Bill Lawrence pickups. That guitar sounded great and I never should've sold it. :(

Keep the pics coming!
 
Dale B":3h67mick said:
I haven't read the whole thread, but everything looks so cool. What kind of pickups are you going to use? The only reason I ask is that I bought a MIM Tele last week and am thinking hard about replacing the stock pickups in it. I've been thinking about those Fralin Blues whatever they're called.

I had a Tele built for me back in the day and the guy who built it used Bill Lawrence pickups. That guitar sounded great and I never should've sold it. :(

Keep the pics coming!

Sorry, I'm not much help there - I don't know the first thing about tele pickups yet. I'm sure Fralin is a safe bet. I might even wind my own after coming this far with it....haven't decided yet...
 
Oh man, 130 year old barn wood for a body would be an awesome piece to hand down one day while sitting on the porch remembering days gone by!!!

So Ratter, lets here your view now on the prices of guitars that get belted out of factories like old man Ford was running the joint.
 
Digital Jams":39qht0ft said:
So Ratter, lets here your view now on the prices of guitars that get belted out of factories like old man Ford was running the joint.

Well considering I could've spec'ed a custom Suhr T for what I've spent on tools so far, you won't find me complaining about prices anytime soon. :doh: :cry:

But Leo was a master of efficiency, I've learned that much...
 
Ok, two problems so far. My neck pocket routing template was a little bit off center. So when I routed the neck pocket in the first body (shown in the posts above), it was a little too far to towards the bass side. It left a little shelf of neck pocket exposed under the treble side of the neck. Not good.

So I reworked the templates a bit to fix that issue and routed the second body. Which I don't mind, because it's a better-looking piece of wood anyway. I knew I would need that second body!

IMG_4015.jpg


Second problem - the drawings I used for the neck and the body came from different sources. The corners of the neck heel were drawn with a smaller radius than the corners of the neck pocket. And I didn't notice until after cutting everything:

IMG_4017.jpg


But the neck pocket is perfect now so I'm happy about that.

I'll have to fix the neck by rounding the corners a bit and then fix the neck templates too...

But, the body routing is done, and the sharper vintage tele roundover on the edges is done too. And it looks like this:

IMG_4021.jpg


Neck and bridge mounting holes will be drilled. No through-the-body string holes, because I'm hoping to find a top-load bridge as used on Fender's CS '59 Esquire. They look like ordinary tele bridges but the strings exit right out the back of the bridge and don't go down through the body:

SqStd-toploader-vintage-bridge1.jpg


Then I can start prepping the body for finish.

The Tru-Oil built up a nice gloss on the neck. But I may have to do a little refinish work after rounding the heel corners...

IMG_4022-1.jpg


The neck still needs tuners. Looks like it's time for some hardware shopping!

Oh, and while I was at it, I did some hole filling on the Barncaster:

IMG_4014.jpg
 
Fixed the neck heel radius issue - now it fits like a glove. Drilled the jack hole in the body as well as the wiring channels, and neck mounting holes in the heel.

And now it's paint...

This guitar is loosely based on a guitar that I played and loved, and should have bought, but didn't - a '59 Esquire Relic that I came across on a used rack a few years ago. So I'm shooting for a similar vibe. And while I'm not necessarily into relic'ing for the sake of looking old, I AM into the feel. The 'old pair of shoes' feel.

This makes life easier in some ways (dust in the paintjob? don't care) and harder in others (I want it comfortable but not overdone.)

In the spirit of Leo, I wanted to knock this shit out like a bean counter. We're not making a McInturff here (not that I could if I tried)....we're making a plank...and the steps I'm following are from a bill of materials from the fender factory in the 50s listing the steps involved that a builder on another forum posted.

Sanded to 320, then primed:

IMG_4023.jpg


Let it dry for, oh, 30 minutes or so, then grain filler. No pics of this step, sorry. I purposely didn't completely fill the grain 100% because I wanted some of that "sunken" old lacquer look, not a new plastic-y look. So, in particular towards the butt end of the body, I left it a little raw. But generally you take the grain filler, which is like a thick liquid or paste, and rub it into the grain and rub off the excess. And that's that.

A few minutes to dry, a little touch of sanding and then the black lacquer color coats:

I just sprayed coat after coat until real lightly until I felt it was a good thickness for what I was going for. Then clear lacquer, then hang it to dry:

IMG_4024.jpg


Let it dry for a couple hours then we sand, sand, sand, sand. And sand some more. At this point, if I were going for a classic factory NOS finish I probably would have let it cure for number of days and then sanded and buffed it out. But again...plank....

So I wet-sanded. 400, 600, 1000. Then micromesh - 1500, 3000, 6000. But no buffing/polishing. At this point it leaves a slick and level finish (except for the aforementioned lack of total grain filling) but still somewhat matte/dull/scratched. Pretty much exactly what I'm going for. A little extra finger pressure here and there to actually bust all the way through the finish, but not too much. And this is where it sits:

IMG_4026.jpg


Tuners and bridge are incoming - I'm leaving the bridge mounting holes undrilled until it arrives. Then we'll be heading down the home stretch...
 
Outstanding work so far man!!

Cant wait to see that when its finished :) :rock:
 
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