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Old 01-21-2012, 10:58 PM
Neil K Walk Neil K Walk is offline
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Join Date: Aug 2006
Location: SWPA
Posts: 6,211

I took a little time today to try and distract myself from my son's situation and fired up the bandsaw to cut laminates for the neck. I cut out a template from a sheet of 1/8" plexiglass earlier in the week and used it to trace outlines on some riftsawn wood that I bought from Rockler a couple of months ago. Then I did a dry-fitting to see how they lined up. The outer layers are mahogany (I believe they're African mahogany,) the inner layers are maple and the center layer is walnut.

Comparing against the plans and the template:

I cut a little extra to the thickness and length of the headstock. The plans also call for a volute which is tricky to cut out close with my little 9" Ryobi bandsaw so it looks ugly but I'm not worried. I may go without the volute altogether though.

I put a fresh blade on the bandsaw but it's got a pretty big tooth and left some bites that I'm going to have to plane smooth. I also need to glue "wings" on the headstock but that will all be hidden by a rosewood faceplate:

The three center layers measure exactly at 3/4" which is what the plans call for the width of the tenon. I have a pre-mortised neck block in the body so I won't know for certain if it will be a perfect fit until I rout away the sides around the mortise:

Once I cut out the wings I'll glue it all together. I may need to buy more of these clamps; they only cost $3 apiece at Harbor Freight. Then I'll move on to routing out the truss rod channel. I haven't decided on a shape to the headstock yet but I really like the look of Collings' headstocks. They're sort of Gibson-esque:

PS: tonight after I visited my son I went over to my friend's shop and finished up the end wedge on the body. It's east Indian rosewood bound by fine BWB purfling strips. For some reason it was much trickier than cutting out the laminates for the neck. Pics to follow once the glue cures and the EIR is sanded flush to the sides.
~ Neil (sofa player, shower singer and basement whittler)
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