SBO 2024: Jupiter Jack

I had a closer look at the neck, and it seems the screw holes for the neck/body joint don't go very deep, don't have a lot of thread left, and don't line up perfectly with the holes in the neck plate. Thinking of plugging and re-drilling.

On the bright side, a lot of the white marks on the back of the neck turned out to be not scrapes through the top coat but just some stuck-on debris that cleaned off fairly easily.
 
Started on a neck pocket routing template. The corners of the neck appear to be pretty close to 1/4" radius, so I might just make the template square if the fingerboard had an overhang or if there were a pick guard to hide under, but this is going to be out in the open so I want it to match as exactly as possible. This is more-or-less the Bondo method but using plywood scraps for the straight sides and substituting filled epoxy for Bondo in the corners. It came out very nicely in the corners but I somehow messed up the easy part and ended up with more clearance than I like on the two long straight sides. I tried to build up those surfaces with wood filler; I'll see what it looks like when it dries, but that was probably a bad decision.
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Back to the MDF top mold which I was avoiding because of the mess. I hand-sawed off the bits at the outer edges that the router couldn't reach, then dressed them level with the curved surface. This didn't need to be done neatly at this stage because this is all about to get routed off, but it was good practice for doing it on the final surface. I got it close with a plane, scraped it level with a card scraper, then sanded across into the curved surface and it came out nicely. You can see that the finished surface on the left looks like a continuous surface whereas the one on the right that I hadn't done yet is visibly faceted.
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I decided I didn't want all that MDF dust inside the shop, so I set up outside on a couple of sawhorses. I shimmed up the workpiece on three strips of MDF that I ripped to 52mm wide, bringing the top of the mold to the target 20mm below the router baseplate, or close enough.
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A project often involves a drop or two of blood. Today that was extracted by the mosquitos, which have returned with a vengeance these last couple of weeks. Careful sequencing is required to get the glasses, anti-mosquito hat, dust mask, and earmuffs all applied.IMG_6275.jpeg

In hindsight, I probably could have set up the bandsaw at an angle and just sliced off most of this waste. But instead I routed about seventeen bushels of MDF dust. Starting with a couple of fairly aggressive cuts of 3mm depth, then 1mm, then finishing up with a final cut of only about 0.25mm deep in rows 10mm apart. I was intending to go over it again perpendicular to the long axis, but it seems smooth enough to make that unnecessary. Plus by that point it was getting dark and the mosquitos were winning.

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Also, I need to find some kind of goggles that fit over my glasses but also work with the dust mask. Any recommendations? I'm not feeling rich enough for one of those full-face dust rigs that looks like a welder's mask, but I sure wish I'd had one today to keep the stuff out of my eyes.
 
Broke out a plane and got the top and back plates jointed. There is still a small sliver of daylight between the halves of the top at one end, but it will be entirely lost in the neck pocket, so I think that's acceptable.

I'm now just about at the point where I should have been at the beginning of the build-off. There's still a week left. Plenty of time.
 
Broke out a plane and got the top and back plates jointed. There is still a small sliver of daylight between the halves of the top at one end, but it will be entirely lost in the neck pocket, so I think that's acceptable.

I'm now just about at the point where I should have been at the beginning of the build-off. There's still a week left. Plenty of time.


Sleep is wildly overrated! :roflmao:
 
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Joining the back using the ‘tent’ method. I’m not crazy about using nails along the edges. Might screw down some plywood or MDF strips instead when I do the front.
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I also decided that close enough wasn’t quite close enough for the jointing the edges of the front. The gap could have ended up either in the neck pocket or down by the bridge, depending on how it was clamped up. I had another go and it came out better this time.

I’ll unclamp the back in the morning and if all is well then I’ll do the front.
 
The back came out nicely and I glued up the top this morning. Sadly I somehow failed to get it clamped down flat, so the two halves are noticeably out of plane. I don’t really want to lose that much of the thickness by scraping or sanding them flush, so I think I’ll rip them apart and try again.
 
Joining veneer edge-to-edge for one of the back plies. Kind of an annoying and fiddly job. The one good thing about it is that you can get away with masking tape for clamping.
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The back and front will each be the originally planned cherry plus two layers of veneer (one birch, one black-dyed mystery wood) which will hide my mistakes, add some thickness, help them hold their shape, and hopefully make for a visually interesting faux binding effect around the edges. The Home Depot birch veneer is not pretty so it’s going to be the middle layer.

Test run with the back vacuum-clamped on the form with an Amazon clothes storage bag. The sheet of Masonite is so I can slide the form into the bag without messing up the ziplock seal on the bag. Then I yanked it out like a magician with a tablecloth.
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Then I sealed it up and sucked all the air out. Then swore, opened it up again, ans put in the breather mesh that I forgot the first time, and did it again. So far so good. Everything is sitting flat and the centre seam is on centre. I’ll leave it for a couple of hours and see if it holds.
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If so, then I’ll glue it up for real. I think I’ll use epoxy because I plan to also use it for grain filling/sealing, so this will hopefully avoid any potential compatibility issues with a different glue.
 
The back lamination seems to have come out nicely. I still need to trim it back to near the final shape, but it looks like I have no voids or other screwups. It sprung back just a touch when taken off the form, but nothing serious.

After a bit more fiddling with the fit of the centre seam for the top, I finally got that well matched and glued up. The two sides are once again a bit out of plane along the centreline, so I'm guessing my centre clamp beam needs a bit more curvature to get enough pressure toward the middle. Must have just got lucky when I did the back. But this time it's close enough and I just sanded out the mismatch.

Glued up the top lamination earlier this evening. Assuming that comes out of the bag alright, I'll be nearly out of excuses to put off bending the sides.
 
Benedetto's book recommends soaking the sides in a piece of drain pipe before bending, but I used an old livestock trough instead, because that's what I have. To the casual observer these might appear to be just any old rocks that I picked up from the driveway, but the sophisticated readers of Talkbass will recognize them as carefully selected Tone Stones.
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This time I followed the instructions and let the bending iron heat up all the way before bending. I had another go at my test piece, which came out not bad, then on to the real thing. I did the tightest bend at the end of the upper horn first, then penciled in marks for the beginning, middle, and end of the next bend, bent that, compared to the template, and so on. No pictures of this because I was just trying to get it done.

Instead of a traditionally full mold, this is a skeleton mold made from shelf brackets, an idea which I probably stole from @2groggy. The body template is held down to the melamine sheet with double sided tape, then each bracket butted up against the template and screwed down. Few brackets where the curvature is large, lots of them where it is sharper. This is definitely not as controlled as a full mold, but it's really not critical whether the side profile exactly matches the arbitrary shape I drew, especially considering that the body isn't symmetrical.
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It came out reasonably well. Maybe slightly lumpy through the curve at the waist where I over-bent it a bit, but acceptable for a first attempt and probably nobody but me will ever notice.

Up to this point I had been working flat on the top of the workbench, then it occurred to me that I could stick one corner of the jig in the vise, which brought it up to a more convenient height and orientation.
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Next, linings. I'm installing these reversed, with the solid side facing in, which should make the sides stiffer and help them hold their shape when taken out of the mold. The top and back are going to be arched, almost meeting at the widest part of the body, so the linings have to follow the curve. The pencil marks are me working out the body thickness at each axial line on the body template, transferring that to the side, then playing connect the dots to approximate the top and back curve. I had myself convinced that I could make the lining follow the curve, but that's not happening, so it's in sections at different angles. That looks pretty janky at this point, but the stair steps will go away when the sides are trimmed to match the top and back, and it will all be hidden inside anyway.

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I also discovered some cracks in the side between the f-hole and end block, but they will mostly get covered and reinforced by the lining. I'll see how I feel about them when the lining is fully installed. Maybe add a veneer reinforcement between the top and back linings. I've had the side out of the mold a few times to mark the layout lines etc., and it really is amazing how much stiffer the linings make it. I knew it would be stiffer, but it really is impressive how much difference that makes.

Next step will be the lining up into the upper horn. As currently drawn the lining runs up to where the side curvature starts to get fairly tight, and it doesn't really want to bend quite that tightly. I could extend the corner block further and cut the lining short, but I think it's a better bet to make the lining conform instead of trying to fit the corner block to the side over a greater area. I'll try putting the lining on the bending iron to persuade it a bit more.
 
Semi-staged photo of bending the lining to fit that curve toward the end of the top horn. I overdid the bend, then broke it while trying to fit it to the side. If you look closely at the photo, you can see where it's already kinked between the third and fourth blocks from my earlier ham-handed attempts. 1728920834716.jpeg

That's fine, I just glued it in anyway. Instead of trying to bend the lining, it probably would also have been fine to intentionally break the last part into individual blocks and glue them all in one at a time like the 'tentallones' in traditional Spanish guitar building.

It's starting to get cold enough out there that the glue is noticeably harder to squeeze out of the bottle. Soon be time to take everything freezable back to the house for the winter.
 
The bass side has more spring back than I initially thought. It's also noticeably more flexible at the points where two sections of lining are butt-joined, which makes sense. That's like cutting the bottom web of an I beam. I'm not sure the spring back and flexibility are related, but I'm gluing strips of veneer across the gaps between linings on the treble side. When that's done, I'll put the bass side back in and do the same. Might help, couldn't hurt. Not too worried about it either way.

Thinking about the f-holes. The top has also sprung back a bit, and while it will not be a problem to bring it back to the intended shape when it's clamped to the sides, I am a bit worried that when the f-holes are cut the edges may want to flare up a bit above the surrounding surface. Considering adding another layer or two of veneer on the inside just in the f-hole area for reinforcement. Also strongly considering not bothering.