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Something I tried many years ago was making linings out of bending ply - a.k.a. wacky wood. They worked O.K. but were very ugly. Having run out of my supply of homemade reverse kerf linings and hearing people extol the virtues of solid linings I decided to give them another go. This time instead of leaving them square I routed an ogee profile on them. I think it improved the look dramatically. They were extremely easy to install and bent enough in all directions to follow the edge of the sides. They were easily and quickly made and I can see myself running off a batch of them in the near future.

Where did you get the whacky woood?

Wacky wood is a fairly standard material used by cabinet shops for making curved millwork, reception desks, etc. I got mine free as scrap (as usual). It generally sells for about 50 to 60 dollars a sheet.
It comes in 4X8, 8X4 or 10X4 sheets. If I was doing a production thing I would get a 10X4 (grain direction), rip it to four 60X24 inch pieces and make 60 inch long strips. My method is to rout 2 long edges, rip them off on the table saw, and then rout the piece again. With four pieces you could rout 8 edges and rip 8 edges alternately, so things would go pretty quick. This would give you enough linings for 64 guitars (less than $1 per guitar). Here is a brief explanation of wacky wood from a commercial supplier:

Bendable plywood, also known as Curve-Ply, Flexply, Wacky Wood and Wiggle wood, bending plywood, is normally made out of hardwood imported veneers with the layers all running in one direction, this allows bend-ability to the panel and can be applied on a curved radius. Our stocked bending plywood is manufactured in the United States and distributed throughout the country.
Bending Plywood
Used in variety of cabinet applications, curved furniture parts and fixtures such as displays in department stores, restaurants, commercial buildings and building of spiral stairways. Most times it will be overlaid in a custom application with veneer, high pressure laminate, for finished columns or other rounded or curved radius surfaces.


Bending plywood comes in thicknesses of 3mm, 5.2mm, 9mm, 12mm and 15mm. Panels come in 4’x8′, 8’x4′, 10’x4′ sizes. Bending plywood can also be produces from other species such as ITALIAN POPLAR AND BIRCH WHICH OFFERS A SMOOTH FACE FOR PAINTING OR STAINING.

Talk with a sales representative from 8am to 5pm eastern standard time or email anytime to sales@packardforestproducts.com. Please include quantity, thickness and contact information, including company name and address. Thank You.

Thanks for that.

How rigid are the rims? If the wacky wood is really bendy, is the frame still a rigid structure like you'd expect from solid linings? In other words,,does the wackynwood take awa from some of the benefits of solid linings?

The rims are very stiff, very close , if not equal to solid linings. And they are so much easier to make and install. Installation was as easy as using the typical commercial kerfed linings. If you have a local cabinet shop see if they have some scraps They will give you and give them a try.

Like the linings from Ryan the wacky wood linings allow you to bend them in both directions to follow the sides. With finger pressure they can be deflected about 1/2 an inch in 12 inches - more than you would ever need for guitar sides.

I routed and ripped enough for 6 guitars in about 20 minutes using a simple set up - a backing board clamped to the material to allow the router to run along the edge. With a better set up you might be able to double that rate.

OK - that looks promising. What glue do you use? Does it work OK with the usual lutherie glues like Titebond?

Yes, titebond works fine. The material bending ply is generally made from is Luan (a.k.a. Philippine Mahogany) so any glue compatible for gluing wood works fine.

I've got 2/3 of a sheet left. It's called wiggle board here. Sounds like an interesting way to use it!

Alex

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"Indecision is the key to flexibility" .... Bumper sticker

Would the side to be glued to the top or back be all end grain?

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A most excellent question!

Yes, it will be end grain. The gluing surface should be great enough that the loss of strength from end grain gluing should not be a problem. Pregluing (sizing) the end grain can minimized the loss of strength.

I made this set of laminated bindings with 1/16" green, blue, red, and black veneers. Thought it was a good idea at the time, but haven't used them yet.


Alex


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_________________
"Indecision is the key to flexibility" .... Bumper sticker

That is a colorful set of linings. If you run a bevel around them you could widen the thickness of the lines.

I did a round over with a couple of basswood sets, Clay. I've got a few languishing projects, and might use the rainbow set for a padauk SJ.

Alex

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"Indecision is the key to flexibility" .... Bumper sticker