This section has only
just been started. It may seem a little disjointed
at some stages.....
I am planning to go through the stages 'as
I go - one at a time' and then at the end edit
it all, adding particular points,
pictures
and references
I may have missed.
Please Treat this Section as Incomplete.
In this Section I'm going to outline the procedures for designing and making a Shaped Guitar Case to fit a specific type of guitar.
Included will be details on the initial Paper 'Patterns', Plywood 'Templates' & 'Patterns', how to make the Internal & External Case 'Formers' using 3/4" (18mm) chipboard, the case itself using special 1.5mm Birch ply and right on through to Lining Materials, covering with 'Leathercloth' and attaching the Case Hardware.
At the end of the project I am hoping to have full scale drawings with notes available !
This same basic process can be used to make pretty well any shape of case.
Part 1 - Making the 'Formers'
The Process.....
Page 1
The Guitar
'Likeness' (essentially
a full size drawing/painting of the guitar as it will be)
and
the Case outline on paper, stuck to a sheet of 3/8"
(9mm) ply
which will form the Templates for the case.
This is a Custom Angel with V
Inlays and a 'Personalised' Truss-rod
Cover.
This is the Template
made of 3/8" (9mm)
Ply for the Inside Former - carefully cut out slightly
oversize using a Fretsaw.
The Template is then carefully sanded using firstly
a Disc Sander to do the majority of the job and
then by hand. It must be exactly right, as this Template is the
'Model' for the
Case.
This is the Ply Template
for the Outside Former -
still in one piece !
( The inside edge still
needs to be trimmed back about 1/4" (6-7mm)
to allow for the Case Wall thickness.)
The Walls,
or Ribs,
of the Case
will be made up from 4 layers
of 1.5mm
Special Pattern Ply
which can be moulded to form the Case Rib
Structure.
In this picture are some of the Component
Parts for both the Inside and Outside
Formers and also a piece yet to be cut. These have been marked out
using the Ply Templates.
All together 4 pieces
of 3/4" (18mm)
chipboard will be needed for both the Inside
and Outside Formers.
Two layers of the Outside Former.
Two layers of the Inside
Former being glued up using standard PVA.
Eight screws are also used in this instance - which also helps the 'line up'.
They have been cut a little oversize,
as the Former will be trimmed
to size with a router.
Two Parts (4
pieces altogether) like the above will be needed for both the Inside and Outside
Formers.
The clamps are 'Cam Clamps' made by Klemmsia
in Germany.
( You can never have too many of these clamps in
your workshop - they're brilliant !)
Continued on Page 2. Please Click Below.....