Summer Build Off 2024 - Lost and Vound

cholyoke

Supporting Member
Oct 1, 2016
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Rubber City
This build is an assembly build.

I am on vacation and while cleaning the basement this afternoon I found this kit I purchased in 2018 when I started to get into making sawdust. It is a 34" scale flying V. I was going to paint it white with black binding and put in three reverse P pickups. When the kit arrived, it had some...problems. It was missing parts and the CNC machine must have been inebriated. The edge of the body had a big divot. The headstock had misaligned tuner holes and the edges weren't symmetrical, which is kind of important for a Gibson-style flying V. Anyhow, I saw something shiny, it got pushed to the back of a pile, which got covered in other stuff and was finally unearthed today.

So in order to make my vacation more exciting, I'm going to finish fixing the tuner holes, rout some squares for two EMGs and see what else happens. If I get the routing, drilling and sanding done before the end of next week, there is a good chance I'll be able to finish it. I didn't put the title on the sheet of paper, but can go back and recreate the moment with the title if necessary.

Specs:
Alder body
Maple/rosewood neck (may dye rosewood black and pull frets).
EMG TW pickups with push-pull switches. Not sure if I will run them 18V or 9V and use a master tone or two tones.
Cheap black bridge and other hardware
Hipshot Licensed 3/8 tuners
Not sure about paint, but I'm feeling purple and white now. Spraybombs for sure.

The pile:

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The wood putty filled divot that needs to be sanded flush:

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The headstock is unacceptably asymmetric. I filled two the holes with plugs made from maple a long time ago. The grain orientation is kind of in the same as the neck (both are flatsawn). They haven't cracked in the several years they've been epoxied in place. I made some new plugs today using a plug cutter and machining them to the right dimension on my lathe. I did not take pictures of this process because lathes are dangerous.

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They fit! I'll epoxy them tomorrow and cut them flush to the headstock.

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The new headstock design I drew this evening. Unrealistically precise dimensions are great. I'll cut it out and use it as a template for trimming everything to the final dimensions.

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Thank you for the vell vishes and as a reward you get to watch epoxy cure:

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Hooray for West Systems. The hardener is still good after a few years! Fancy saw to cut off the excess:

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And I can't use the damned thing:

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To the sander: (Not an action shot for safety)

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Wood putty to the rescue!

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Love the smell of that stuff! Reminds me of huffing glue. Tomorrow some sanding and it will be smooth as butter, ready for my next act of butchering.
 
Yup, or take a playing card, cut a hole in it the size of your dowel, place it over the dowel with the dowel standing up through the hole and then trim it off.

Flush trim saws don't have the teeth "set", meaning the teeth aren't leaning out to the sides. They are "flush" with the sides of the blade body, that way they don't dig in to the work piece.
 
FYI: Cutoff saws don't have teeth jutting out like your does - it may not be a cutoff saw - or - a piece of masking tape the material side could keep the teeth off the surface.

Yup, or take a playing card, cut a hole in it the size of your dowel, place it over the dowel with the dowel standing up through the hole and then trim it off.

Flush trim saws don't have the teeth "set", meaning the teeth aren't leaning out to the sides. They are "flush" with the sides of the blade body, that way they don't dig in to the work piece.
Thank you for the suggestions. the big saw is not the right tool for the job despite being sold as a cut off saw, so I bought a smaller version (see below).

I've been working on this off and on as I did other things, but did not update the thread. Lots of progress pictures below.

I reshaped the headstock near the nut so both sides were the same shape. Lots of rasp and filing, which are pleasant tasks. A bit of whittling and some sawing, epoxying a chip back in place and we end up with a nice looking headstock!

IMG_5269.JPEGIMG_5270.JPEGIMG_5271.JPEGIMG_5273.JPEGIMG_5327.JPEGIMG_5328.JPEGIMG_5329.JPEG

Ready to drill! Kind of convenient placement of the bandsaw to help support the headstock while drilling. Checked my measurements twice and made the marks and the holes ended up too close to the sides because I read my drawing incorrectly. I also grabbed the 1/2 brad point bit instead of the 9/16 bit. Fuuuuuuuuuu....family website! Well, I cut some plugs and epoxied them in the holes with the grain aligned parallel to the grain of the headstock.

IMG_5330.JPEGIMG_5331.JPEGIMG_5335.JPEG

I got to use the new cut off saw to get rid of the excess plug/epoxy and sanded them down. I just put more epoxy on the holes to fill the gaps a little more after sanding. Hopefully I can drill again tomorrow!

IMG_5345.JPEGIMG_5349.JPEGIMG_5351.JPEG

I've also made routing templates for the battery box and control cavity cover from some scrap MDF. More filing for straight or curved edges. Pickup templates not shown. Probably going to start making holes in the body tomorrow, too. Paint should arrive next week, so things are progressing. The marks are on the front of the body to make sure control cavity and battery compartment don't interfere with the pickup routs. These marks are also on the back of the body.

IMG_5312.JPEGIMG_5343.JPEG

Not sure if I will use the cheap and functional high mass bridge that came with it or a tune-o-matic style bridge. TOM looks more Gibsony, but cheap bridge is easier. We'll see what happens
 
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Thank you for the suggestions. the big saw is not the right tool for the job despite being sold as a cut off saw, so I bought a smaller version (see below).

I've been working on this off and on as I did other things, but did not update the thread. Lots of progress pictures below.

I reshaped the headstock near the nut so both sides were the same shape. Lots of rasp and filing, which are pleasant tasks. A bit of whittling and some sawing, epoxying a chip back in place and we end up with a nice looking headstock!

View attachment 7018660View attachment 7018661View attachment 7018662View attachment 7018664View attachment 7018666View attachment 7018667View attachment 7018668

Ready to drill! Kind of convenient placement of the bandsaw to help support the headstock while drilling. Checked my measurements twice and made the marks and the holes ended up too close to the sides because I read my drawing incorrectly. I also grabbed the 1/2 brad point bit instead of the 9/16 bit. Fuuuuuuuuuu....family website! Well, I cut some plugs and epoxied them in the holes with the grain aligned parallel to the grain of the headstock.

View attachment 7018669View attachment 7018670View attachment 7018671

I got to use the new cut off saw to get rid of the excess plug/epoxy and sanded them down. I just put more epoxy on the holes to fill the gaps a little more after sanding. Hopefully I can drill again tomorrow!

View attachment 7018674View attachment 7018675View attachment 7018677

I've also made routing templates for the battery box and control cavity cover from some scrap MDF. More filing for straight or curved edges. Pickup templates not shown. Probably going to start making holes in the body tomorrow, too. Paint should arrive next week, so things are progressing. The marks are on the front of the body to make sure control cavity and battery compartment don't interfere with the pickup routs. These marks are also on the back of the body.

View attachment 7018665View attachment 7018672

Not sure if I will use the cheap and functional high mass bridge that came with it or a tune-o-matic style bridge. TOM looks more Gibsony, but cheap bridge is easier. We'll see what happens
Unlike your errors, my pitifully simple projects don't suffer so catastrophically as you must feel afterwards. You have my total sympathy for making what we acknowledge are avoidable mistakes - it's the story of my life!

Would a veneer front and back on that headstock face cover the plugs and save your finish objectives?

Glad you got the right cutoff saw, tho. You're still eons ahead of anything I could do..soldier on!