A build re-using old guitar wood. My COVID-19 "stay home" project

[H165]

This build, nicknamed "Patches", will be a deep-body SJ Brazilian Rosewood 12 fret slothead - long Martin scale. I started working on it in 2011, but I had to put the body aside partially finished. I caught sight of it yesterday while looking for a long-term distraction from the current COVID-19 inactivity.

Patches' body is made from salvaged parts. I started repairing flat top acoustic guitars in late 1964. I began buying old Brw guitars for repair and resale around 1980. The "donor" guitar used for Patches was built by M. (Morris?) Covault in 1969. Loosely modeled after a Martin D-28, I bought it at the Rose Bowl Flea Market in 1995. It was rough, not playable, but it is solid Brw. In 2009 I started playing Harmony H165 guitars built in the 40's. These guitars have a "figure 8 SJ" design. I wanted a Brw guitar of similar design so Patches got designed to fill the bill. The only parts used from the Covault guitar are the Brw back and sides. Started by taking things apart:

[Flat5]

Congrats! The rosewood looks incredible. I’m looking forward to seeing how this will turn out!

[Ozzy the dog]

Wow, that's some heavy bracing. I always think salvaging is more work than using new materials but well worth it. Look forward to seeing this develop.

[CoffeeFan]

Yeah, I'd say you've got your work cut out for you. Can't wait to see it when it's done!

[H165]

The kerfing, braces, and blocks were removed, the rosewood was cleaned and stripped. The asymmetrical sides were re-bent, to roughly SJ form in my Fox-designed side bender. The sides were left deeper than the Harmony design. The body was shortened slightly to accommodate the length of the sides and the new shape. There is a long crack in one of the sides, and a crack in the back; both repaired and cleated. I found two book-matched worm holes; one in each side, which were hidden with wood filler. I inlaid both with Brw patches.

[GeoffStGermaine]

Looking forward to seeing this one come (back?) together!

[H165]

The bracing is all new Sitka. The top is from the Martin factory; from the 1950's. The sound hole location was uncut, but marked; I moved it a bit towards the tail block to accommodate a 12 fret long scale neck. The braces were repositioned to meet the design criteria. They are forward shifted Martin style X brace pattern; scalloped. Just under .300" thick. Tone bars and finger braces are 1/4".

[H165]

I like the figure and color in the wood. There are small "wings" on the back wood, joined near the outer edges of the big bouts. There is a crack in the back; repaired and cleated. Fairly tall braces for the wide body.



I had this huge old length of picture frame molding made of flamed maple, so I cut it up and put it in my bender for the binding. Using plain "rope" purfling all around.

[H165]

Starting point for 2020: Here are the parts patchworked together and put on the shelf 9 years ago:

[j. Kinnaird]

Cool project! And kind of inspirational. Got me thinking

[cigarfan]

Thanks for sharing. A reclamation project will be interesting to watch.

[CoolerKing]

What an awesome project! Those braces look like they could pass hurricane window inspection

[H165]

Jonh Arnold and Bryan Kimsey sometimes add or use a small flat "compression" brace between the neck block and the top cross-brace, under the fretboard extension. It attenuates one of the problems contributing to the need for a neck reset. I'm adding one here. Two large brace blanks; the one on the right ended up fitting best, with a firm press fit between block and brace:

[Jwills57]

Very cool project and quite an undertaking! 12-fret guitars are really captivating creatures. I'm anxious to see how this turns out. Well done. Best, Jack

[H165]

Those braces look like they could pass hurricane window inspection

Huh. Do we know each other outside this forum, or was this just an offhand remark?