So for the amusement and hopefully benefit of anyone out there that may be considering buying their first kit or building their first guitar (particularly the ones with little to no experience with tools or wood), I decided to write a little story in my spare time...
I love guitars. I've always loved them... From the moment I picked up my first guitar, I was obsessed and drawn to the instrument. I wanted to know as much as I could about them and what made them tick. Naturally when I got a little older, I realized that these guitars didn't just sprout up from the ground. Someone somewhere out there was making them. The beauty of Google eventually helped me find luthiery and subsequently this forum. It was fun reading up on the topic and seeing many of the discussions and conflicts in theory. I lurked here and on some other sites absorbing information and building my own set of beliefs regarding guitar and luthiery. Eventually I had found myself with some cash in hand and I decided to go ahead and try my hand at building my first guitar.
But how best to go about it? I had heard several discussions about building from a serviced kit vs. an unserviced kit and also what kind of woods to use and what tools were needed for building. These are issues that there seem to be an endless number of conflicting opinions about. I read and read and read and formulated a list of tools that I needed (or THOUGHT I needed). Even though I read a lot, I didn't bother doing a whole lot of actual research on the matter. I bought chisels, planes, a band saw, a drill press, a random orbital sander, files, etc. I must have totaled over $3000 in tools alone that month all before I had a piece of wood to use them on and before I even knew how to use and maintain them. I also bought a popular book (Tradition and Technology) that I skimmed once after I bought the tools and before I bought my kit.
Now that I was somewhat fully equipped to build, it was time to choose what kind of guitar to build, where to get the kit from, what kind of kit to buy, and which woods to use. Mind you, this was all being thought about AFTER buying the tools. We all love good things and we all love the idea of a masterpiece. I am certainly no exception to the rule, though I might take it a bit further than most. I decided to go with a kit from LMI mainly because of their Kit Wizard, which let you customize the features. I decided to go with a service OM kit and I selected Master Grade Engelmann Spruce for the top and 1st Grade Cocobolo for the back and sides. I selected basically the highest grades and most expensive woods for just about everything else from the bridge to the fingerboard slots. Expensive = Good, right?
So my package from LMI came and I quickly opened it up and set it down on my makeshift bench (a slab of plywood on top of a tool box in my laundry room). At the time I was working so I would only be able to work on it on weekends. So the weekend came and I went downstairs to work on the guitar. I popped in Robbie O'Brian's DVD and skimmed through the first few steps. I was now ready to start building. There was only one problem. Over the course of the week, the sides had sprung back enough so that they didn't match the plans. I hadn't made a mold because I didn't watch the DVD until the day I was going to work on the guitar and I hadn't paid mind to humidity issues either because I had skimmed over those parts so now my sides were sprung back and my top and back were warping. So what am I to do? I weighed the top and back down with heavy books and ran out to Home Depot to buy some plywood to make a mold. I quickly encounter another problem in the fact that I had watched the DVD, but obviously I didn't pay attention to it and didn't know how to use the bandsaw because I glued 3 layers of 3/4 plywood together before trying to cut it in the bandsaw. For those of you that haven't tried this, generally a Ridgid 14" bandsaw is not happy when you do this... Particularly when it wasn't set up properly in the first place and I knew nothing about that since I had bought it and never really read that you generally didn't want to just use it out of the box without adjustments....
So 2 bandsaw blades, a lot of burnt plywood and a good amount of foul odors later, I finally had a crudely cut mold. But then there was the problem that it was crudely cut, so what does one do? Well if you're me in that situation, something in you possesses you to take the entire thing to a spindle sander to shape it the rest of the way. Those of you who are experience probably already see where this is going... Long story short, I spend a good hour trying to make everything nice and smooth and I end up with 2 sides that are not even close to symmetrical anymore and don't match the plans. Solution? Well I went back out to Home Depot to get more plywood and do the same thing again... THE SAME EXACT WAY... By the way, I found out a few weeks later after rewatching the DVD in detail that Robbie hadn't glued everything up and thrown the whole thing in the bandsaw...
Finally I now have a somewhat symmetrical mold that somewhat matches the plans, but my sides still don't fit in the mold because they had sprung back. Try as I might, I simply cannot seem to push them in without cracking them so now I'm forced to bend them again. Unfortunately while tooling up, I hadn't bought a pipe or iron so what do I do? The logical people in the group would probably just go out and buy one or make a makeshift one. I decided to try to bend it with a curling iron... Yes, a hair curling iron.. So not only do I have absolutely no experience bending wood, but I'm attempting to bend a set of Cocobolo sides on something that is meant to bend hair, not wood. On top of that I haven't shelled out for a vice so I'm holding the iron to the wood with my right hand while using my left hand and the ground to try to bend it. Guess what happens? CRACK!
Luckily I didn't crack the side in half, so I proceeded to go ahead with a sloppy superglue job to bring the side back together. What do I do now? I decide to just go ahead without a mold at all instead of getting an iron and doing things properly. I glue up the sides together with the blocks on each end and then realize that I should have probably done at least a LITTLE bit of trimming down because now I have a lot of wood to take off to bring to flush to the blocks. Again, I wish I had paid attention to the DVD because something in me possessed me to try to bring it flush with a combination of a hack saw, a dozuki saw, and a coping saw... Needless to say I found myself overcutting and then proceeded to sand the entire thing down on a radius for a whole day to get good edges... Now the guitar is really thin from the extra sanding, but that's that.. time to give myself some encouragement, learn nothing from my experience and move onto the next step to suffer from the same mistakes.
It's time to work on the back. Since my guitar's shape has changed, I have to see if the back still even fits (it would've probably been a good idea to check this before I glued those two sides together, huh?). It does, but only at a slant, but what can I do, right? Let's run with it. So I cut the braces, shape them on the radius dish, make the back strip and glue it all on. I could've sworn I remembered everything from my skimmed reading and watching of the DVD. Wait... Now I have my back strip running parallel in grain to the back instead of across and my braces have been cut the wrong way grain-wise and I have massive runout. I haven't rounded off the corners either. Time to fix it.. Oh wait.. I already glued the back onto the sides...
Oh well, what can I do, right? It's my first guitar after all... nobody said it was going to be perfect despite the ridiculous amounts of money I spent on really good wood...
Now I left a little overhang, but I feel like taking it off now because that's now how a guitar should be. I vaguely recall hearing people talking about using a router so that sounds like a good idea and I bought a router so I might as well use it. Wow... this router is heavier than I thought it'd be. How do people do this? Oh well, let's give it a shot. I put the router up to the wood and turn it on for the first time. HOLY CRAP! Suffice to say I got a rude awakening from the power of the thing and I was completely unprepared for the sheer power and noise. After going out of control for a split second, I manage to turn the thing off before I damage anything. I guess I should clamp my guitar down for this (I didn't have it clamped before)... Notice at this point, there's no reference to the book or DVD because I'm trying to feel it out for God knows whatever reason... It might have been easier if I had a router table... Or if I had paid attention to all these people that talk about routers saying that the box would say LAMINATE TRIMMER as opposed to 2HP PLUNGE ROUTER. Details, details... So there I am with my 2HP router in hand, guitar clamped down with 2 wooden cam clamps and a flush cut bit being completely unaware of how a router should be operated. I think most people will predict that this won't end well and it didn't...
I'll end this story there because that's where the story actually ends. I gouged out a good piece of my side when the router went out of control, got pissed off, and put the entire project down for a few months. A bit later down the road, I registered to attend a 3 week course at Vermont Instrument Makers, where the instructors prevented me from making a lot of mistakes and quickly corrected the ones I did make even though I was probably one of the worst students they've ever had. I learned a good amount of patience and the value of keeping costs down on the first few builds. I came out with a guitar, a better understanding of luthiery, and the realization that I had well over $2000 worth of tools that I probably didn't need at all...
For those of you that are looking to build their first guitar or indeed have already ordered or started their first, I would really recommend that you take things slowly. It's easy to get excited or overestimate your abilities. Take the time to buy a book or DVD first and study it before doing anything else. DON'T SKIM!!! A lot of my mistakes if not all of them could have been avoided by simply not skimming and doing some proper research step by step. You may read this and just write me off as an idiot, and I'll certainly agree that in retrospect I was, but regardless of how extreme my case was many people make similar mistakes (though they probably do less damage and learn from them faster). Thinking back, I'm really fortunate to even have my fingers considering how dangerously I was using these tools... Another thing I'd like to note is that if you're starting out, really take advantage of the great advice people have to offer on this forum. Don't just read it, but think about it and realize that people say what they say for a reason. I wrote off a lot of people on this forum and dismissed them and now when I look back, I honestly do wish I hadn't.
Despite how embarassing it is for me, I decided to write this not only because I had free time, but in hopes that others will learn from my own experiences. If I could do things again, I'd do them very differently... I'd have done my research first, then bought the wood, and bought the tools as I needed them as opposed to the other way around. Even though it would have taken me longer than buying them all at once, I would've realized what exactly I needed and why I needed it, leading me to make better decisions overall.
Anyways, I hope you guys had a laugh or two and I hope others may have gotten something out of this. ^^;; This forum is great and I'm really thankful for how much I am learning each day from reading.