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Kalliope neck carve

Kalliope neck carve.

I took some time last week to make improvements to my old neck holding jig for carving necks.  The 1" thick plywood it was made from had cupped badly so I sandwiched it with two pieces of 3/8" plywood on either side to straighten it out.  This also significantly increased it's rigidity, which makes carving much more efficient.  The more your carving jig deflects, the less wood you remove with each stroke.  I also took a torch to the jig and burned it to give it a bit of character and then sealed it with a coat of shellac.

Kalliope 001's neck is in the jig, the neck for Rogue 005 is on the bench in the background.

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Chubbuck neck build :: fingerboard glue-up

Chubbuck neck build :: fingerboard glue-up

I use a single-action truss rod on my acoustics and push relief into the neck when I glue up the fingerboards.  This way I'm able to extend the range from relief to straight to back bow upon tightening the rod.  I also use hot hide glue for this glue-up.

Rogue 005 in the front, Kalliope 001 in the background (clamped).

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Neck prep :: using a drum sander to thickness pegheads

Neck prep :: using a drum sander to thickness pegheads.

Here I'm thicknessing the rear of the headstocks for Rogue 005 and Kalliope 001 before I laminate them.  When I worked at Santa Cruz, they had a shop-made drum sander that works awesome for quickly thicknessing pegheads.  I have always thought that I was going to have to build something similar for myself but have gotten around this task by using a Wagner Safe-T-Planer in my drill press.  This time around I decided to see if I could use my new-ish drum sander.  I was extremely pleased to find that the in-feed roller on the drum sander is easily removable.  Much better results with this method in less time, but super dusty.  I used a fan to attempt to direct some of the dust into the hood but I'll need to rig up something better next time. 

Note: the Safe-T-Planer method works fairly well, but it requires more time to clean up the transition from head to neck. 

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Chubbuck acoustics :: Rogue & Kalliope mock up

Chubbuck acoustics :: Rogue & Kalliope mock up.

The first Chubbuck guitar builds in the new shop are getting ever closer (finally!).  The necks for Rogue 005 (left) and Kalliope 001 (right) need their rear head laminates and fingerboards glued up before being ready to carve.  So far I'm really happy with the new Kalliope design.  I tried to borrow the lines of the Rogue and scale them up to a larger body.

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