Interesting day today. I started early by loading the second walnut panel into the CNC and started the top half of the guitar carving. Then I unwrapped the book-matched set of buckeye burl boards that Bill bought for the top.
There are a couple of nasty large holes at the top, that I need to avoid, so I over-laid the outer ring from the bottom carve that I did yesterday. It looked like I would just miss if I set it up just right.
I had a few more smaller holes and loose knots so I taped the back, at their locations, before glueing up the panels.
The tape will prevent the epoxy from leaking through the board. I mixed up some 2-part, 5 minute epoxy to fill the loose knots and a couple of smaller voids.
While that was drying, side 1 finished on the carver so I flipped the board and proceeded to carve side 2.
When the epoxy dried, I scraped, planed, and sanded the buckeye smooth.
I wiped all of the dust off with Naphtha so I could glue the panel to the walnut that just came out of the carver.
I want to save any of the burl that I can so I traced the outline of the guitar then applied double-sided tape outside those lines.
I spread glue within the outline, then attached the burl, along with a 3″ piece of maple of equal height to the bottom edge. This was required to center the good part of the burl so I could avoid the holes. I used every clamp I could find and a couple of clamping cauls in an attempt to press all of the glued surfaces together.
While that was drying, I decided to make the control cover from a piece of scrap that I salvaged from the Baby Sitar build. Since it was a funky shape, I decided to CNC a template of the cover from 1/4″ plywood instead.
With the pattern cut, I taped it to the scrap of burl and rough cut the shape on the band saw.
I sanded the burl flush to the template with the spindle sander.
In a matter of minutes I had a perfectly fit control cover.
After the glue-up had cured enough to carve, I loaded it into the CNC and taped over the holes, so the sensors wouldn’t get confused. After an hour or so, the top carve was complete, so I cut away the tabs and went to line it up with the bottom piece…
Things were going so well too… I realized that I had accidentally created the back piece in reverse. Could be worse though. I didn’t mess up the top. The burl is really expensive. If I had screwed that piece up, I would have been out $160. Luckily it was the back piece. I am only out four hours of labor.
Well, I am a little frustrated now and that is when mistakes happen, so I am going to knock off for the day. Hopefully I will have time tomorrow to rebuild the back piece…