Noah James Publishing Po Box 1695 Bensalem PA 19020 Copyright © 2002 by James C Donahue All rights reserved. No part of this book may be reproduced in any form or by any electronic or mechani- cal means including information storage and retrieval systems. Except in the case of short quotations embod- ied in articles or reviews, without written permission from the author or publisher. Library of Congress Catalog Card Number: 98-91198 Table Of Contents Chapter One: Tools, Jigs and Templates Page 6 Chapter Two: Guitar Maintenance Page 15 Chapter Three: Guitar and Bass Parts Page 26 Chapter Four: Pickups and Electronics Page 36 Chapter Five: Guitar Design Page 45 Chapter Six: Making a drawing Page 54 Chapter Seven: Designing and Constructing Necks Page 61 Chapter Eight: Fretting and Fretwork Page 71 Chapter Nine: Basic Building Page 84 Chapter Ten: Pickguards Page 91 Chapter Eleven: Small Shop Building Page 94 Chapter Twelve: Carving Tops Page 100 Chapter Thirteen: Paint and Finish Page 106 Chapter Fourteen: Factory Guitar Repair Page 114 Chapter Fifteen: Small Factory Production Page 128 Chapter Sixteen: Large Factory Production Page 134 Chapter Seventeen: Acoustic Guitar Production Page 144 Chapter Eighteen : Wood Information Page 156 Information Supplies Page 161 5 My experience in the guitar business is exten- sive and other then-washing dishes at a Chinese restaurant, and playing in bands work- ing with guitars is the only job I have ever had. I studied graphic arts in high school, after high school I spent three years in Bucks County College studying music and music theory. I studied Jazz guitar but after the third year my teacher told me that I should just play rock because I really had no interest in Jazz, bas- cially I would only practice the scales and learn chords that I liked. In 1984 I left college and was employed by Ibanez guitars. Since I started in the guitar business I began learn- ing how-to setup instruments, my job was to check and setup 50 guitars a day. After one year I was promoted to the guitar repair department for five years until I became the manager of repair, teaching new employees repair and restoration. Though the late 1980's into the early 1990's I had my own repair business out of my house and I became known for working on vintage guitars. Many local people from the east coast of the United States would only let me work on their guitars. I have built, repaired or customized guitars for many people including Steve Vai, Joe Satriani, Larry Mitchell, Andy Timmons, John Petrucci, Paul Gilbert, Frank Gambali, George Benson, Pat Metheny, John Schofield, Paul Stanley, Gerald Veasley, Gary Willis and at least 50 more people worldwide. From 1991 I was put in charge of Ibanez worldwide quality control from our Hoshino USAoffice in Bensalem Pennsylvania. I have visited Japan, Korea and China over thirty times, visiting over thirty-five guitar factories through out the world working with these factories to help them understand basic guitars from a market and playing point. Each factory has their own production style so I would only try to help them improve the prod- uct, how the improvements were done was up to the factory. Now in my career I am now working designing and building prototypes for Ibanez. I also have my personal Ibanez Vintage Web site at http://www.ibanezvin- tage.com . Since the late 1980's I have been involved with designing somehow almost all the Ibanez guitar models. I real- ly love guitars and other then my family, my life's passion is building and designing guitars. Because of my busy lifestyle it is impossible for me to play in a band because I could never devote the time involved to learn and practice songs. I still practice playing guitar everyday, and both my office at work and home are both filled with guitars hanging on the walls. Since I am always making something I still get to practice and try news things almost daily. I own somewhere around 35 guitars I have a hard time counting them because so many are throughout the place, under beds, in closets or even out on loan to my friends. Of these 35 I made about 25 of them for myself and I have never sold a guitar, I still own my first Harmony Rocket that I bought for $35.00 from a friend. 6 Tools, Jigs and Templates 7 This chapter is maybe the most essential in this book. My father taught me about tools when I was very young, I couldn't understand why he would get so mad when I would take a hammer and not put it back or leave it in the woods. Now I understand there is nothing more important that a persons tools. I keep mine under lock and key; I never try to let them out of my site. I have actually spent hours looking for tools that fell behind the bench. I learned don't blame anyone until you check every option. My father used only craftsman tools that he bought at Sears but almost all my specialty tools I have made or modified from something else. Today thanks to companies like Stewart Macdonald and Luthiers Mercantile, these types of specialty tools are more easily available, however, I tried many new tools but they don't have the same feel as the ones I made. I tried to count my tools, but it is impossible. I have hundreds that I have made, bought or been given over the years. Throughout this book you will see many tools, jigs and tem- plates that I or someone close to me have made. I can only hope that these will help you to have some ideas for tools to make building easier. If you have any good ideas, you can always let me know I am always looking for good tools. Where do I get my tools? Many of my tools are Japanese because they have a much better selection of tools than we do in the United States. They seem to have special tools for everything. I started working on guitars using Japanese tools back in 1984, and when I went to Japan someone took me to a department store called Tokyu Hands. 8 They have everything not just tools, but there is nothing that they don't have from pens to toilet paper holders. I was amazed they had so many files and bits. For example in the US you need to buy nut files from a special- ty store, but in Japan you can purchase the sizes individually. Dremel bits, they have things we only dream of like actual sanding drums that are 1/8"/1/4." These are great for cleaning out neck pockets without changing the shape. I travel to Japan a least twice a year on business, and I always make a trip to Tokyu Hands to get new tools. For example, they have Magic Markers that are great for doing touch ups in every color. I bought my fret saws right over the counter and that is all I will use. They have many size hole reamers that you could never find here as well as different sizes of end nippers that can be modified to pull frets. In the USAI do purchase tools from Sears, Home Depot and True value hardware. Luthier supply houses like Stewart Macdonald and Luthier’s Merchantile are great places to find specialty tools in the States. But, even still most of my tools have been modified somehow even if it is just making all my screwdrivers magnetic or modifying my files by putting handles on them. This is a collection of fretting tools all hand made, The blocks are made from mahogany scrap. The upper block on the left is a broomstick handle with first felt then rubber around it, I use it for rounding the frets after leveling the tops. Next is my fret-cut back file for putting the angle on the fret ends. To the front is hand made fretting press cauls that I made years ago. These have the fret radius in them, and I use a drill press to push the frets in. In the center with the holes is a fret holder. Before the days of fret benders we use to bend and cut each fret to the size and shape of the fret- board, this holder holds 24 frets that I shape to the exact radius of the fretboard. This is a collection of tools I made for set up. Just Allen wrenches set in dowel rods. First, they are much easi- er to use than a standard angled wrenchs, second they are easier to find on a crowded desk and best of all then can be setup on a work bench for easy access. To do this I just use a grinder to make the wrenches straight and drill into the dowel the correct size and super glue the wrench in. The upper left tools are hand made scrappers that I make from old hack saw blades. Next is my custom nut cutting template that someone before me made, it also works great for removing Gibson or acoustic nuts. I hold it against the nut and give it a quick tap with a hammer. The far right is one of my fret saws modified with a depth cutting con- trol I made by gluing paint sticks on it , this helps keep the fret slot even on both sides. 9 This was designed by Fritz Katoh and is used for checking the neck set angle on acoustic gui- tars. This is basically a straight edge with a handmade gauge on the end. When laid across the frets the guage tells what the neck angle is set at. Many people use the same type of jig but with a fixed shim of say 14mm and use this when they are actually setting the neck before gluing. These are fretboard protec- tion jigs for leveling frets on painted fretboard's like a Strat with a maple fretboard. The template lies over the fingerboard, and the frets come up through. This allows you to level and crown the frets without causing damage to the fret- board finish. Here is a collection of small tools, The top two on the left were actually made by a Japanese person before me that had my work bench I don't know who it was but thanks. They are used for raising the bridge on an Ibanez Gibraltar II bridge, and the second on is for tightening a 3-way toggle switch to the body without a pair of pliers that can scratch or deform the nut. The next jig is for marking the bridge stud location for a Floyd Rose that is counter sunk in the body. The others are my modified hacksaw blades that I ground down into scrapers. This is a Fritz Ruler designed by Fritz Katoh. This tool has a nut cutting templates on one side; the other side has a metric ruler and string height adjustment. The tip is 0.5 mm for checking the nut height of the strings off the first fret. The purpose of this tool was to control factory setups at all of our manufactures and distributors. 10 JIGS If you will do anything more than once from drilling a side jack to presetting intonation, make a jig. I have jigs for everything. I started making jigs because I realized that if I measure something there is always a chance of making a mistake, like measuring a Lespaul bridge and then realizing you drilled the holes at 25.5" from the nut. For these reasons, I make a jig for almost every possible process. Some jigs I made include a center jig for side jacks that marks a center hole inside for drilling, bridge and stud loca- tion templates, machine head installa- tion, string retainer, intonation, neck set, top arch, mounting ring holes. For shaping necks on the pin router I have a jig that shapes as well as has the truss rod channel template in it. To make a jig first figure out what you need to do, for example install a standard tremolo. Make a jig from Plexiglas that starts at the nut and has the location of the six bridge screws in it. Acenter line runs down the middle of the jig that you line up with the fretboard dots at the center of the guitar. Put six screws in the exact location on the template and press down this will give you the position of the bridge screws. Basically, you measure the jig once and from that point on, all your bridges will be in the exact same location. I made this jig for machine heads, because when I replaced necks sometimes I had a hard time getting the tuners straight. This was a pain so I milled out a piece of wood to the exact location of the six tuners. I put the tuners in the jig and set the neck on it, put the nuts and washer's on the posts and tighten. This places all the tuners in a perfect line. Next I just drill the screw holes and add the screws. Another thing that I had a problem installing off set was the Floyd Rose string retainer bar on the headstock. It seemed that no matter how hard I tried to drill the holes the retainer would be uneven. I made a small piece of Plexiglas with the two screw hole locations that I hold against the fretboard before I put the top lock on, so the holes are marked perfect every time.