Building the Grand Concert


June 25, 1999.....I built the mold today. I've made many different types of molds, but this one was the easiest to do. I followed an idea from the Lutherie Tools book (published by the Guild of American Luthiers) this time.

I first made a template strip of one half of the guitar shape. I used tempered hardboard and drilled three indexing holes in the template. Then, I traced the template four times, onto 3/4" plywood, including the indexing holes. Next, I used a jigsaw (it doesn't bind, as my little bandsaw tends to) to cut out the four pieces, about 1/16" outside the traced lines. After drilling the corresponding indexing holes in the plywood pieces, I then attached the template to one of the pieces using dowel pins through the indexing holes. I used a 1" carbide-tipped flush-cutting router bit with a ball-bearing roller, to rout the plywood piece flush to the template. I did the same to the other three pieces. It came out great!!!! All four pieces came out exactly the same, and nice and smooth! I had never had that kind of uniformity using my little Delta 8" bandsaw.

After I had my four pieces, I glued and nailed ten 2" tall spacer blocks in between the plywood pieces, again using the indexing holes to line it all up correctly. Finally, I screwed 3" mending plates to join the two halves together. When I need to remove the guitar body from the mold, I only need to unscrew the mending plates.

I'm still waiting for my supplies for this it's a good opportunity for me to start working on my side bending form.

 GO TO.....

  1. Intro Page
  2. Making the Mold
  3. Making a Side Bending Form
  4. Side Bending!
  5. The Side Set
  6. Beginning the Neck
  7. Top
  8. Back
  9. Soundbox
  10. Binding
  11. Fingerboard
  12. Finishing the Neck
  13. Finishing
  14. Nearing the End...
  15. Stringing 'er Up!!!

Return to Projects Home Page