Build Thread- Broadcaster cnc build

[ehawley]

Hi all!!

This will be a multi build thread .My first here at the CNCZONE! You can check out another build I did at the TDPRI site here It will be a broadcaster build in the traditional sense, also a 60s' verneer neck complete with pearloid markers and maple cap neck thrown in. (I would like to replace some purchased necks with ones that I built myself).

The wood for this build came mostly from my good friend Dwight . Dwight lives in Arkansas. He aquires some mighty fine wood! He is a great builder also! Some great mandolins and teles!

The inspiration for the truss rod anchor came from Jack at the TDPRI site. He sent me a picture of a truss rod anchor which I used to make mine for the broadcaster neck. I altered it abit. I'll explain as we go along.

I will be winding the pickups for this the same way the broadcasters of the 50s were done. 43 guage wire for both the bridge and neck pickups.
Electronics will be the "Blend" control.
Tuners will be Kluson single line. I am also machining the jack cup! Should be fun!

[ehawley]

First, the drawings.....

Here is the Broadcaster body drawing...



Like the first broadcasters, there is no wire channel route under the pickguard. The treble side of the neck pocket is "straight" which will result in the "shelf" showing under the neck.


The Broadcaster neck drawing...



The profile...



not quite a boat (V) neck, nor a "baseball" bat either, but a nice chunky neck.

I made significant changes to this drawing from my originals in my last build at TDPRI!
Another fellow that I met through there was David Eichelbaum. He worked on the "nitty gritty" section in the Blackguard book with Nacho. Talking with him on the phone I learned some particulars about the early 50s' necks that are reflected in these drawings.

The Verneer and maple cap neck drawings...



These will be a nice "C" shape!

[ehawley]

Truss rods....
The rods, as well as the anchors, are made from high carbon drill rod. The adjustment screw is made from 12L14 steel. The screw should strip before the rod itself. That way you can easily change it out if any problems "happen"!
Tap and die...



Standard stuff. The thread on the rod and anchor end is 10-32

Threading the end...



The anchor end is only threaded for about 5/16 of an inch. The adjustment side is threaded about 1 inch.

Tapping the anchor and adjustment screw...

[ehawley]

The anchor....

The anchor is very simple! It is cut with a 120 degree cutter.
First you turn it to the diameter you want. I turn mine to .360 dia. Tap it, and hold it in a collet block...



Set the 120 cutter on center and cut away!!



Turn the block 90 degrees and cut again. You end up with an anchor that looks like this...

Mounting on the rod...

[ehawley]

Ready to be peened...




And here it is peened and finished...





Should do the trick!!

Here is the anchor for the verneer necks. Self explanatory...

[ehawley]

Here is the wood for the body...





One piece swamp ash.
Thanks Dwight

Here is the wood for the verneer (rosewood) and maple capped necks...





Man o man look at that flame!! The wood is .94 thick. Great for the verneer and capped necks!
Thanks again Dwight!! One of these babies will be headed back your way!

[ehawley]

Here is the wood for the broadcaster necks...





Just plain old hardrock maple from Willard Brothers, where I buy most of my wood.


Well...I hope this wets your appetites. Next week will be CNC time for the body. I have to clear some real work out of the way. (ain't that always the case)
As usual all the files, (dxf, dwg, parasolids, pdf) will be posted soon.
Thanks all
Cheers
ED

[Mike Stevenson]

ehawley,

My appetite is very wet. I'm looking forward to watching your progress.

[fatal-exception]

Cool man. Should be a cinch to cnc that body and neck. I have a full set of drawings for a Telecaster, back in the day that I did everything 'Amish' style. My truss rods look remarkably similar. I think I used 3/16" drill rod.

Cant wait to see some wood chips of your project!

P

[Mike Stevenson]

For you guys who don't feel like machining your Truss Rod from scratch for a $10.00 item you can buy it from Stew Mac here:

http://www.stewmac.com/shop/Truss_ro...Truss_Rod.html

[glwilliams]

Fantastic Ed! I followed your '53 build on the other forum and it was great. I'll be watching this one closely.

Greg

[ehawley]

Originally Posted by fatal-exception Cool man. Should be a cinch to cnc that body and neck. I have a full set of drawings for a Telecaster, back in the day that I did everything 'Amish' style. My truss rods look remarkably similar. I think I used 3/16" drill rod. Cant wait to see some wood chips of your project! P

Thanks, the chips will be flying next week! Yea..teles are great to build. I've done 13 already and my business partner has done 4.
cheers
ED

Originally Posted by Mike Stevenson For you guys who don't feel like machining your Truss Rod from scratch for a $10.00 item you can buy it from Stew Mac here: http://www.stewmac.com/shop/Truss_ro...Truss_Rod.html

True...but the fun is in building...I always try and build as much as I can from scratch! This way when my son gets all my guitars, he will have as much of me in them as possible!
cheers

Originally Posted by glwilliams Fantastic Ed! I followed your '53 build on the other forum and it was great. I'll be watching this one closely. Greg

Thanks Greg....Im posting this on the other site as well. Because I use Solidworks, Mastercam, and CNC every day for my business I thought it would be appropriate to post here also!
Thanks again all,
Cheers
ED