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Posted: Mon Jun 14, 2010 4:26 am
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[Strangled sounds from Ceri] ... ... ... OK. On the last page you did say you wouldn't need to re-route the pickup cavities, and if some of us heard that as "won't be re-routing at all" - well, I guess that's our own fault, isn't it? :? ... :lol: :lol:

Damn, it hurts to see those 50 points go elsewhere, though! First I'd heard there even were points on the Forum. I thought it was just a dollar a post and that's it...

Right, well: I'm going to be seriously interested to see the excavation prior to insetting that tasty bit of wood. Out with the camera, if you please!

BTW. Regarding carpentry skills: a gentleman who can build his own router table and run up all those nice templates has the skills for anything. Carry on! :D

Cheers - C


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Posted: Mon Jun 14, 2010 6:07 am
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Thanks Mr C!
Ceri wrote:
[Strangled sounds from Ceri] ... ... ... OK. On the last page you did say you wouldn't need to re-route the pickup cavities, and if some of us heard that as "won't be re-routing at all" - well, I guess that's our own fault, isn't it? :? ... :lol: :lol:

"Ahem"...Does that sort of thing happen often? If so, I feel really sorry for Mrs Ceri's nephew :wink: :lol:
Ceri wrote:
Damn, it hurts to see those 50 points go elsewhere, though! First I'd heard there even were points on the Forum. I thought it was just a dollar a post and that's it...

Shuuush, aslong as you don't tell Nik, you can have 50 points too for being a good sport :D

Enjoy!

Andy & Randel the Cat

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Posted: Mon Jun 14, 2010 9:22 am
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Ceri wrote:
Damn, it hurts to see those 50 points go elsewhere, though! First I'd heard there even were points on the Forum. I thought it was just a dollar a post and that's it...
Andy wrote:
Shuuush, aslong as you don't tell Nik, you can have 50 points too for being a good sport

Thats the spirit Andy, points for everyone, you don't play in goals by any chance ?? :roll: :lol:

On the build, as a plan B that looks the business 8) Randel's whiskers


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Posted: Mon Jun 14, 2010 12:58 pm
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ripitup555 wrote:
Thats the spirit Andy, points for everyone, you don't play in goals by any chance ?? :roll: :lol:

On the build, as a plan B that looks the business 8) Randel's whiskers

Eeeek!

Looks like we've been rumbled Randel....

ripitup555, You can have 50 points too (just don't tell Nik or Ceri!)

Andy & Randel the Cat

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Posted: Sat Jun 19, 2010 11:42 am
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Andy, hows it coming?

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Posted: Sat Jun 19, 2010 12:24 pm
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Andy.

We can forego the 50 points if you'll kindly advise me on turning a black and decker workmate into a router table.

Where did you get all that perspex?

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Posted: Sat Jun 19, 2010 2:11 pm
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Impulse7 wrote:
Andy, hows it coming?

I'm putting an update together as I type this. Should be up tomorrow (maybe tonight). You get a mention mate, but you'll have to wait to find out why :wink:

nikininja wrote:
Andy.

We can forego the 50 points if you'll kindly advise me on turning a black and decker workmate into a router table.

Where did you get all that perspex?

No problem!

I got my perspex out of an 8ft x 4ft heavy duty notice board that got cracked and had to be removed and replaced at work. Waste not, want not! You can pick up some fairly large sizes form B&Q but I have no idea of cost.

I reckon it's do-able. Just make sure your Workmate opens wide enough to fit the router base with no obstructions below and then make a top like mine. If you want to use it for other projects (like picture framing etc.) I'd recommend making it a little longer than mine.

The tricky bit is going to be the height adjuster. Shouldn't be to hard to make a three piece frame from 3” x 2” timber and then bolt that to the MDF board. (I can knock up a quick plan if you need one)

Let me know if there's anything else. Hope this helps

(Oh yeah, you get to keep those 50 points!)

Andy

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Posted: Sun Jun 20, 2010 2:15 am
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Howdy!

Right then, I've been a busy bunny this week but have had time to do some work on the botched bridge cavity, so here's an update for you all with plenty of pics as requested! (apologies in advance if some of this is a bit boring).

Its early on Sunday morning as I finish this so this morning (and through out the build below) I will be mostly drinking.....

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Bloody strong coffee!

A few things to mention...

Just a few words on how we figured out how to fix my bridge cavity.

I'm going to award 50 points to Impulse7 for posting his Morgan Strat Thread

It was that thread that gave me the idea for an inlay to cover the botched bridge cavity which in turn saved this body from an unhealthy dose of lighter fuel and a lit match! Thank you :D .

Once I'd made the decision to make an inlay to cover the bridge cavity I needed to find something to make an inlay from. So while walking into town with Mrs Andybighair, we walked past a tiny shop called Acacia Designs, selling hand made wooden items (furniture, chopping boards, art work, etc) On closer inspection we noticed what looked like a workshop in the back and a sign next to the items that said..

“GO ON! TOUCH THE WOOD!”

Which I though was great! There was this stunning piece of birds eye maple which had been beautifully finished with Danish Oil. It looked almost 3D! Anyway Mrs Andybighair then suggests that I see if they have any off cuts that I might use a as an inlay. 50 points to Mrs Andybighair! Turns out the owner, Jack (who made all the cool stuff) happens to have a few boxes of off cuts from the guitar industry. (Weird huh!?!). I explained my situation and He very kindly sold me that thru-neck off cut that featured in our little guessing game. He also gave me a few carpentry tips and showed me how to make plane-scrapers(?..not sure what their called) out of old saw blades. Very cool chap Very cool encounter.

Down to business!

Botched Bridge Cavity Solution

In order to insert my inlay I need to make a decent template. It took two attempts to get this right. First time round I marked out the inlay on an MDF off cut left over from the router table and just cut it out with a saw to the best of my abilities. Lets just say Randel the Cat was not impressed. So on the second attempt I screwed in place three nice straight pieces of timber around the inlay, making sure they are a good tight fit (I can assure you it was very tight fit :D) like this..

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I then drilled a couple of holes in the corners and roughly cut out the middle of the MDF board with the jig saw. I then set up the router table and got dressed up as if I was about to defend Tokyo from giant baddies! :D.

Image

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With the template cutter I rout out the remaining edge flush with the attached timber. Once the timber is removed I sanded screw holes flat so it looks a bit like this...

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A quick test to see if the inlay fits (OMG its perfect!) Now we line up the template on the body and clamp it down.

Image

Hit a small problem here as the base plate for the router doesn't span the width of the template. This slot needs to be as perfect as I can make it so I can't risk the router tipping and creating an uneven slot and I can't use the router table as the clamps will get in the way.....

…..But I know someone who has already sorted this problem for us.....

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Genius!

Image

As you can see above the “Ceri Base Plate Method” works a treat! With that sorted we can rout out a nice level inlay slot.

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I'm cutting about 3mm at a time. The pic above shows the last pass before I get to the desired depth of 25mm

Once we're done with the router the template is removed. Very minor hic-cup here as my body measurements were out by just over half a millimetre which is why you can see the nasty bit in the pic below where the routers not quite gone all the way through to the trem spring cavity. It was supposed to go all the way through and end up flush with the rest of the cavity. I might have been a little ambitious in my planning here :D . Not a problem as we can tidy that up when we come to re-route the bridge cavity later.

Image

Another quick test to see if the inlay fits (OMG its still perfect! Woo whoo!)

Now my template has rounded corners which we need to loose....

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...so out with the chisels to tidy them up so the inlay fits all the way in.

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Nice.

We are now ready to glue the inlay in place. I hoovered and brushed out the inlay slot ready to apply some wood glue mixed with a little water.

Image

With the wood glue applied, the inlay is a tight fit and requires a final knock in to place with a rubber hammer (yes I did eye the Nunchaku just for a second :D). With the inlay glued and inserted into its correct and final resting place we have some lunch and come back to check to see if I've pulled this off

“And the straight edge says.....

Image

“Andy, You've done good mate” !

That was a seriously freakishly accurate bit of routing, if I do say so myself. I can quite believe its turned out this well. I can only put this down to all the Mojo you lovely people sent my way went it all went Pete Tong before (that and I suspect Randel the Cat may have “Mind Raped” me and upgraded my carpentry skills during that trippy episode a few posts back....)

So this is where its at for now

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Still got a bit to do. I'll post more soon.

Enjoy!

Andy

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Last edited by Andybighair on Sun Jun 20, 2010 8:20 am, edited 1 time in total.

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Posted: Sun Jun 20, 2010 5:51 am
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it's going to look absolutely gorgeous when you're throuh with it.


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Posted: Sun Jun 20, 2010 6:34 am
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Andy - Beautiful work my friend. This thing is gonna look sick!

~Kong

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Posted: Sun Jun 20, 2010 6:44 am
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Oooooh luverly job, can't wait to see that glossed up Andy, nice find, that little shop, you found a little gem there by the sounds of things


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Posted: Sun Jun 20, 2010 7:05 am
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Andy,

Looking good. Cannot wait until the next installment.

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Posted: Sun Jun 20, 2010 7:14 am
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That looks Cool!

-T


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Posted: Sun Jun 20, 2010 9:29 am
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Wow...so when you add the finish this will look really nice. I know it is a log way away but what are you going to do for a finish? Also Andy, did you get my email????

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Posted: Sun Jun 20, 2010 2:23 pm
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Thanks for all your kind words people! :D

I should get a bit more time in tomorrow so you might get another update in the next few days (I still can't get over how well the inlay fits!).

ripitup555 wrote:
Oooooh luverly job, can't wait to see that glossed up Andy, nice find, that little shop, you found a little gem there by the sounds of things

Yeah, it was a classic case of Serendipity. Mrs Andybighair had dragged me into town to try and cheer me up after the router incident and we just stumbled across it. Still can't get over the fact the guy had boxes of off cuts from the industry. I mean, how cool is that! :D

Xhefri wrote:
Wow...so when you add the finish this will look really nice. I know it is a log way away but what are you going to do for a finish? Also Andy, did you get my email????

I'm going to be using Tru Oil for the finish as my last attempt at spraying was poor to say the least! Also I reckon oil is the best way to show off what a lovely piece of timber we have here.

I've replied to your e-mail (sorry it was a bit late!)

Enjoy!

Andy & Randel the Cat

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