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Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Hello all,
I've been a member for years and posted a build thread when I built my CNC awhile back. It never occurred to me to see if there was an instrument forum here. Lo and behold, there is!
Well I've been using my CNC to build all sorts of things since I "finished" it (they're never really done, are they?). The latest one is using it to help me build a replica or tribute or ... i don't know, homage? ... Here's the basic jist...
This specific build is very important to me as an enormous fan of Eric Clapton. I'm going to attempt to replicate the 1964 Gibson ES-335 that Eric bought in that same year.
There will be a lot of challenges along the way, but my hope is to pay homage to a man who has been a very large influence on my life both in music and in lifestyle. This is my attempt to share the impact Eric has had on my life and that his intention to be a good steward of the Blues has certainly been a success to my ears.
I started this in november and have been filming every single minute of the build as I go from testing processes to cutting project parts to fixing errors and remaking mistakes. It's not a short series, by any stretch. My main goal in all this filming is to show the ENTIRE process - not just skip over from one success to the next. I'm not a teacher, I'm not really a luthier. I'm learning - and you're watching that as I go. This whole build is a big challenge for me but it's fun and I love all the lessons I'm learning. It just so happens I'm walking out to the shop and hitting record...
Today, part 21 posted ... I post a new episode every week and if folks don't mind, i'd like to keep updating this thread as new episodes come out. I'll have questions along the way and maybe you guys can help guide me through my struggles. Here's today's video:
https://www.youtube.com/watch?v=_3Uk4ElVxCc
And if you're really looking for some time to kill - here's a link to the playlist up to this point: https://www.youtube.com/playlist?lis...itEaGnWq5BTfWa
If it weren't for this place, I wouldn't have my CNC - and i wouldn't have the capability to build this guitar - so thank you for being a great community. I lurk 99% of the time and absorb the stuff that gets posted and my hope is that some of this will contribute to the wealth of information this forum offers. Thanks for watching! :)
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
In honor of Eric Clapton's 70th birthday, a special release of the guitar build video series... Early!
Happy birthday, Eric, and may you have many more. Thank you for the inspiration, the motivation and the musical therapy you've given me since I was a kid.
This video is a pretty good one, too. Lots of work done on the neck - getting the tenon fitted into the body properly.
https://www.youtube.com/watch?v=8Wq1iKCtlYA
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Part 23!
First, a quick cleanup of the outer edges of the body to prepare for the binding. Then we steam out some dents and dings on the surface - got some great footage of that. After that, I finish cleaning up the fret slots on the fretboad. Finally, the loose fit of the neck tenon bugs me enough to redo it with a FAR better fit and get the neck angle set properly. This was a big one!
https://www.youtube.com/watch?v=zJzoXmV4qPE
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Another big episode - in this one, I get the fretbard cut to length and install binding on the end of the fretboard. Then I route the rabbet for the binding on the body and give a quick overview of the body routing jig.
After that, I start doing binding installation on the body and while the glue's drying, I start the process of shaping the back of the neck. Finally, we see the results of binding the body and get another lesson the hard way.
https://www.youtube.com/watch?v=d7Q8-bONmh4
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
A followup on the failed binding and some cleanup of that. I also cut out a radius gauge for helping with the back of the neck shape. Also, I fair up the shape of the headstock some more - knowing i'm not quite done, yet.
https://www.youtube.com/watch?v=zs8_pjK52r4
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
This episode starts with checking the fretboard mounting.
Then I begin shaping the neck to the templates at the 1st and 12th.
Next I shape the rest of the neck and heel bout.
Finally, drill the tuning machine holes and clean up the headstock.
https://www.youtube.com/watch?v=FtLQZkQ2zro
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
It's time to start tests for headstock inlay. I wasn't pleased with the fretboard binding after shaping the neck - so i decide to remove what's there using the CNC and then reinstall the binding after that. Finally, more headstock inlay tests start...
https://www.youtube.com/watch?v=QnjEikjKd0U
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
First we see the results of the neck re-binding. Stick on the end binding. Then clean up the binding. Also, more headstock inlay tests - this time with a new material. Then we re-drill and install the side markers and true that up. Also some more fret slot cleaning. Almost ready for frets!
https://www.youtube.com/watch?v=7VpPhpZeTPg
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Headstock inlay test results. And a monumental phase, it's time to start testing colors for the finish! This episode is the first half of all my color testing adventures. Big doings!
https://www.youtube.com/watch?v=q_KncdARHqQ
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
beamerweb
Great to see you crafting such a fine instrument. Thanks for sharing your video's
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
More finish testing. Mostly finding the right colors and looking to make the grain pop as much as possible. Trying some crazy things with an under-coat of unusual colors, as well. Learning a lot about Transtint and the way the maple responds to it.
https://www.youtube.com/watch?v=22XTUZpl3rg
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Continuing the color testing. Lots of samples, lots of reds. Also worked on the figured test pieces as well. Plenty of color in this one!
https://www.youtube.com/watch?v=bXBzDiZivN8
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Sorry for the late video!! I rushed to get this one together in time. You'll be glad to know there's NO FINISHING AT ALL in this one. I actually split that out, skipped ahead a little bit and will post the skipped portions soon, for those interested.
In this video, though, very big step - long overdue - finally gets done and with FANTASTIC success. The body binding returns!
https://www.youtube.com/watch?v=kouFHDsK_fM
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Looks very nice! Great job :)
Hub
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Hey thanks, Hub! I wondered how many folks here are really gettin' anything outta these ... i appreciate the feedback! :)
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
The sordid color testing tale FINALLY comes to a close in this second half of part 32. I split it off to appease those of who have had enough of it. Unfortunately, the reality is it took this much to reach a conclusion on color - and this entire build is 100% of the effort, good or bad, warts and all. I am sensitive to the fact that this part was pretty un-enjoyable. Imagine being the one going THROUGH it!
I promise this is the end of the color testing footage - you'll have to tune in next week to see which color I did finally choose, though :)
https://www.youtube.com/watch?v=XgpfWVFGYZs
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Your videos are very good with great tips & tricks :) I'm going to make a guitar (or two) too when I get the chance. Thanks a lot for sharing :)'
Can't wait too see (and hear) yours finished! :)
Hub
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
In a little mini-episode, I get started modifying the wiring harness to fit the 335. This requires some de-soldering and some re-soldering by a complete amateur hack who can't solder to save his life. I later learn a valuable lesson but for now, check out this little tidbit of footage of the wiring :)
https://www.youtube.com/watch?v=3RRycEtUL4Q
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Another 2-part episode this week. In this first part, we review where we are with everything. I also discover an oops and have to figure out a solution.
https://www.youtube.com/watch?v=GcF2p_MCT8s
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
The real gem of this episode is part 2 - this is a huge step. Frets! From bending the fret wire to the proper radius, notching the frets for the binding, installing each fret and leveling and dressing each fret. This episode covers the entire fretting process. VERY big milestone! :)
https://www.youtube.com/watch?v=qQ-iZnrCJWM
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Awesome job. You are really doing great work. I do have a suggestion for you for later builds that may help. I also sand my frets like you did to get them smooth. Instead of the micromesh pads to get the final polish I use a dremel with a small buffing wheel and jewellers rouge. It gets a great high polish and takes a fraction of the time. Anyway great job. I'll keep watching.
Ben
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Thanks Ben!
You know, I have the buffing wheels and all that for my dremel - and I even think to use it for that very purpose once in awhile -- but sure enough, when it came time to DO it, the thought slipped my mind completely. I don't often think of my dremel for much - maybe that should change. :)
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
This is probably the most exciting episode to date, at least for me. We start by finalizing the neck pocket shape and break angle. A quick basic sanding of the front of the body while the whole surface is easy to access. Then, after a bit of stalling, the neck is finally glued onto the body - the two parts become one!!!
https://www.youtube.com/watch?v=NiEaEt0t02k
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Now that the neck is on, we tackle flushing the bout up with the body. After that, it's time to take care of that little issue with the body being just slightly too narrow for the fretboard.
https://www.youtube.com/watch?v=ZJPdhcQFmCs
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
This episode tackles the headstock inlay once and for all. We try some very cool techniques with v-carving and also try out a new vacuum fixture I designed. I also may or may not have lost what's left of my mind somewhere along the path...
https://www.youtube.com/watch?v=CtTiKJGbCuE
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Today we start out with a little more headstock inlay testing. I think I've finally got the process that I was seeking. In between, I tackle some issues I noticed with the wiring - and cause a few more. Big lessons in soldering learned. Finally, the headstock inlay testing comes to fruition - a very cool headstock plate emerges!
https://www.youtube.com/watch?v=Z9DzxmXAM7g
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
The headstock plate gets glued to the headstock first. Then, while that dries, some more wiring fun. I think I have figured out how to solder, finally. Though, I did find one oddity in the schematic that I need to remedy. First go at fishing all the stuff through into the body as well - that was the opposite of fun. In the end, good learning, good proofing of process.
https://www.youtube.com/watch?v=LuNsMMsfjsQ
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Trimming the headstock and filing/rasping it flush. I definitely should've done this sooner - like before the rough shaping was done on the headstock to start with. Lesson learned!
After the headstock plate is flush and all the holes drilled out, I set about making a nut and fitting it. Big floppy saw bouncing around near the headstock - eek!
As if that wasn't enough, I also reclaimed my truss rod access - more sharp things around that inlay - crazy. Yeah, not gonna do it this way ever again. Also mounted the cover plate, while I was at it.
Got a lot done this episode!
https://www.youtube.com/watch?v=oHyRUk3XmlA
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Even more awesome progress this episode. With the nut in place, it's time to start placing the bridge and tailpiece. I also widened the access port for the wiring which really helped thread things through easier.
After that, we revamped the wiring to fix the lost ground and generally clean things up. Plus we fix my issue with the 'dependent volume' controls - I much prefer the ability to mix the pickups so I switched things slightly to choose INDEPENDENT and VINTAGE wiring scheme:
After that, the pickups get mounted properly and we see the whole thing with almost all the hardware installed. Getting VERY VERY Close!!!
https://www.youtube.com/watch?v=IanEjPw-8f4
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
First, we make up a pickguard template then set about actually making the pickguard including the bevel. After that, we mount it and the strap pegs. Then the tuning machines ... a monumental step occurs... very important episode! :)
https://www.youtube.com/watch?v=fPTrhj3oXbM
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
If last episode was awesome, this one is even better. First it's time to break everything down and prep for the finishing process! After the final sanding, pore filler goes into the mahogany. Then, the brown color goes on and gets sanded back. Finally, the red comes out and shellac after that. This was a pretty densely packed episode for sure. We're definitely in the home stretch now!!
https://www.youtube.com/watch?v=iik0qoxSLV4
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
We're really into it now! Red's dry and it's time to clean up the binding a bit. Then a coat of sanding sealer goes on - with another lesson! After a little break, I come back and on goes the lacquer! The guitar looks amazing at this point and I'm really really getting close, now!
https://www.youtube.com/watch?v=0tZRQWL158M
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Now that the lacquer has cured for 3 weeks, you guys are about as close to realtime as I can get you while still leaving time for editing. The next step is to block the lacquer flat and get rid of all that orange peel while hopefully not burning through it into the color! I tried real hard to get this all done so that while you're watching this I'd be hearing it play for the first time. I didn't quite make that but I'm filming next week's episode as you're watching this, so now you're only a week behind. It's almost done!
https://www.youtube.com/watch?v=o6KDRGRGbcg
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Looks like it came out well so far!
A little late for you, but thought I'd let you know how to scrape binding the way it's done at the Gibson factory (I used to work at the flattop factory and had worked at pretty much every position in the finish department while there short of spraying the color). What you do is get yourself some heavy duty glass microscope slides, then use your fingers to space the corner of the slide the appropriate distance from the edge of the binding to keep it even as you move along to strike a line between the binding and where the color starts. This line is generally just inside of the edge of the binding. If you look close on a Gibson, you'll notice that there is a slight overlap of color on the binding, so that should be considered normal. When we did these at Gibson, you'd spray color over the binding 100%, no taping over the binding, then scrape all the color off the binding using the glass slide. If you look closely at Gibsons, you'll notice a little bit of a "trench" where the binding meets the color, which is where the initial cut into the color is made with the corner of the slide. Depending on the skill of the person doing the scraping, this trench can be nearly invisible, or so deep that a lot of clear is required to fill it (pissing off everyone else in the finish department that handles the guitar there-after, since it has to be filled flush) . Once the inner line is made, you clear out the color with the slide more flat, though still angled a little forward. These glass slides are less likely to chatter than a knife blade and truly just as sharp/precise. I consider them a "must have" for any craftsman, but they remain almost a trade secret. You can actually shave off wood with them, with exceptionally clean results and more speed than sandpaper, or plane down finishes where there may be a ripple or run, etc. Once you learn to use them, glass slides are something you'll wonder how you got by without. I get them at my local university book store.
If you're ever doing another Gibson style specific finish, feel free to ask and I'll give you step by step directions as to how it was actually done at the factory, and the slight adjustments necessary as it relates to doing it at home (we had IR ovens, lacquer that is run through a heating plenum to make it as if it had been reduced, etc.).
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Thanks very much for this! I sprayed nitro lacquer and it seems to be fairly period correct - but the genuine process is probably quite involved, huh?
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Quote:
Originally Posted by
beamerweb
Thanks very much for this! I sprayed nitro lacquer and it seems to be fairly period correct - but the genuine process is probably quite involved, huh?
I wouldn't say it's that complicated, just specific and something that has evolved over their 100+ years of building guitars! Some of the things they do are hard to replicate at home just because the products are not available to hobbyists. For example, I have not found a pore filler that I think closely replicates what they use (used on mahogany, rosewood, etc.). I have resorted to making my own using oil based paint and Cabosil and it's pretty close.
It's funny, though. Since I have worked on perhaps thousands of Gibsons while I was there, my finishes now look like Gibson finishes no matter what kind of guitar I spray. I have a very hard time replicating a Fender finish, just because it's equally as foreign to me as it is to most everyone else who hasn't worked at Fender. I'll be helping my son spray a '68 Dodge Coronet we're working on for his first car (he will likely never drive it until after college), and I have no doubt it's going to end up looking like a Gibson instead of a Mopar!
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
LOL - that's awesome. I've been building furniture for a while and i keep trying different finishes over the years. I have to say, without a doubt, lacquer is my favorite to work with. I live in a dry area, so that probably helps my success rate, though. That and shellac - two of the most well behaved finishes i've ever used.
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
Home stretch time! First, I got some polishing compounds from a generous auto body friend of mine to get the super shine I'm after. After a little testing, I go after it with reckless abandon. Then, it's time to put the hardware on... carefully! After that, I try to take a final shot at fishing all the wiring back in - which needs a little help but ultimately it made it in. At the end, it's all over but the stringin'!!
https://www.youtube.com/watch?v=p0dKnkBAWco
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Re: Building my 2nd Guitar - A 1964 Gibson ES-335 tribute/replica
So it's gonna be kinda hard to say anything about this besides YOU WILL HEAR IT FOR THE FIRST TIME!!!! WoooHooo!!! First, I set it up and all that, though. Then some actual noise - I'm not very good at playing so please don't throw rotten veggies at me. I did the best I could! Well that's about all there is to say, eh?
This build is complete!
https://www.youtube.com/watch?v=YmZxPj9FedY