In rare form…

Ok, maybe not rare, but its a form.  I on the other hand, may be in rare form.  I’ve been replacing lyrics in my head all day.  Currently “Hazy shade of winter” by the Bangles, somehow involving Jonathan Winters, but I don’t have all the lyrics worked out in full yet.

Anyhew…

I made the form for the Gibson OO build.  I’ve seen many different ways people do this and basically figured out what I liked and added an alignment feature based on how large injection molds work.

Used my dad’s shop.  He has the tools that make it easy, such as a belt sander and oscillating spindle sander.  I traced the form onto some 3/4″ ply.

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Screwed four pieces together and cut them out on the band saw.

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Used the sander to smooth to the line.  Split the forms into two halves and blocked with pieces of 2×4.  Air nailer and glue to attach the blocks.  I dadoed an alignment block on the top and bottom where the forms come together.  This makes a very positive 2 axis alignment and is much easier than aligning dowels.

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Added the top layer of plywood.  Cut the overhanging blocks and the outside perimeter on the bandsaw.  Then smoothed with the sanders.  Made interior clamping cauls with the excess.

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Took the mold back home to my shop.  Sealed with shellac and put on trunk hasps to keep the mold together.  Its really solid, but comes apart in a snap.

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Dog sitting at my parents tomorrow, so I should have more shop time there.  Need to work on resawing more maple backs and sides.  I can also cut basswood neck and tail blocks as well as kerfing if I have time.

Still up in the air on neck wood.  I really like flamed maple with flamed maple, worried about how brite it will sound. I could also go straight mahogany or spanish cedar on both the maple and cherry versions.  Thoughts?