Portland Guitar Co.

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Portland Guitar Co. | Portland Oregon | Contact Jay Dickinson-503.245.3276 | jay@portlandguitar.com


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Finished Build

Orchestral Model OM 2.12.58

ForWalt H.

Walnut Body
Sitka Spruce Top
Mahogany Neck
Pistachio Fretboard, Bridge, and Headstock
Maple Binding
Herringbone Purfling
Gold Frets & Gotoh Tuners
25.4 Inch Scale Length

Page 5


( 192 ) 30-June-2013

After the braces have been glued in place the guard ring around the sound hole needs to be reduced to size.

( 193 ) 30-June-2013

I use my oscillating sander for this job.

( 194 ) 30-June-2013

I sand the ring flush with the sound hole.

( 195 ) 30-June-2013

Now I am working on the contra-rosette.

( 196 ) 30-June-2013

I have created a template out of clear plastic.

( 197 ) 30-June-2013

I carefully cut out each piece and arrange them in order.

( 198 ) 30-June-2013

I have to be very careful that each piece is identical. Here I am holding down the template over the veneer.

( 199 ) 30-June-2013

Here is a look at the assembled contra-rosette.

( 200 ) 30-June-2013

To finish it off I am installing black binding.

( 201 ) 30-June-2013

Here is how it will look through the sound hole.

( 202 ) 30-June-2013

I put a layer of lacquer on the ring to bring out the pop.

( 203 ) 30-June-2013

Here we are installing K&K pickups.

( 204 ) 30-June-2013

I like to include a brace to constrain the cables.

( 205 ) 30-June-2013

 

( 206 ) 30-June-2013

I use the router table and a special fixture to route out the heel channel in the heel block.

( 207 ) 30-June-2013

I route the channel with several passes.

( 208 ) 30-June-2013

The heel of the neck will fit in here along with the attachment hardware.

( 209 ) 30-June-2013

The tail graft channel get made with the same fixture.

( 210 ) 30-June-2013

The tail graft mirrors the shape of the heel.

( 211 ) 30-June-2013

I use a disk sander to put a bevel on the reenforcing strip that will be used on the back.

( 212 ) 30-June-2013

Here I am using the go box to glue in the conta-rosette and the reinforcing strips.

( 213 ) 30-June-2013

I measure the side braces to fit in between the kerfing.

( 214 ) 30-June-2013

A couple of clamps hold them in place as they are glued down.

( 215 ) 30-June-2013

And a little hand sanding cleans up the glue marks.

( 216 ) 30-June-2013

Before gluing the back onto the sides I clean up and glue marks on the back.

( 217 ) 30-June-2013

And I install fiducial buttons to help align the back as it will be glued down.

( 218 ) 30-June-2013

Here I am marking the position of the attachment hardware in the heel channel.

( 219 ) 30-June-2013

A few holes get drilled.

( 220 ) 30-June-2013

And the wood inserts get installed.

( 221 ) 30-June-2013

The neck adjustment hardware hole gets drilled.

( 222 ) 30-June-2013

And a wood insert is screwed into place from the rear.

( 223 ) 30-June-2013

A look at the hardware.

( 224 ) 30-June-2013

And the label gets glued in place.

( 225 ) 30-June-2013

Here I am taking a slice of the pistachio to use for the heel tail graft.

( 226 ) 30-June-2013

The band saw is used to cut out the tail graft.

( 227 ) 30-June-2013

I carefully hand shape the tail graft blank to fit into the channel.

( 228 ) 30-June-2013

A bit of glue secures it in place.

( 229 ) 30-June-2013

And after it is dry the overhang gets trimmed off.

( 230 ) 30-June-2013

Getting ready to glue the back on to the sides I have sanded scallops into the over hang so the bolts will clear.

( 231 ) 30-June-2013

A bit of glue goes on the kerfing.

( 232 ) 30-June-2013

And tape to hold the back in place.

( 233 ) 30-June-2013

Then the bottom flange gets bolted down. This will apply even pressure all around the rim.

( 234 ) 30-June-2013

A little bit of squeeze out.

( 235 ) 30-June-2013

And I clean up the squeeze out before it dries.

( 236 ) 30-June-2013

After the glue dries the assembly comes out of the form.

( 237 ) 30-June-2013

Before I trim the overhang off I install a block in the bottom of the heel channel to guide the router through the heel channel.

( 238 ) 30-June-2013

I use a small router to trim off the over hang .

( 239 ) 30-June-2013

Everything is flush.

( 240 ) 30-June-2013

Before gluing the top on I round off the guard ring in the sound hole.

( 241 ) 30-June-2013

Then the kerfing gets a bit of glue.

( 242 ) 30-June-2013

The ends of the braces that will contact the sides also get glue.

( 243 ) 30-June-2013

And then the top is pressed into place in the form.

( 244 ) 30-June-2013

A c-clamp makes sure the fretboard shelf gets pressed into place.

( 245 ) 30-June-2013

And after the glue dries it comes out of the form.

( 246 ) 30-June-2013

And the router is used again to remove the overhang.

( 247 ) 30-June-2013

I take advantage of the angle of the heel channel to create the fretboard shelf wings. These will help hide the seams when the neck is attached to the body.

( 248 ) 30-June-2013

A look at the back.

( 249 ) 30-June-2013

And a look at the top.