1959 Les Paul replicas - build progress

shredaholic

New member
Now that I've been back from Uni the past week, I've managed to actually get started on my various building projects. The first few days I spent getting further acquainted with some of my tools, and also purchasing various accessories to help keep the tools in shape. Since most of my most useful tools are the ones left to me by my late Grandad who used to build boats, they needed a bit more care and so I went about removing rust, cleaning, tuning, honing etc on them.

First off there was the spokeshave, which I found like this:

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It was quite rusty, and the blade edge was dull and left horrible chatter when used. Even with a sharp blade, there's the worry of leaving dirty rust marks all over the wood being worked on. After applying several coats of rust remover, scrubbing with a wire brush, and repainting with hammerite (not quite japanning but it did the job perfectly) here's the end result:

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Carves through wood like butter, and looks a bit more presentable too. This is definately now my favourite hand tool, it's just so easy to use and will be invaluable for carving necks out in a matter of minutes. Plus, since this photo was taken the blade is now razor sharp and like a mirror thanks to oilstones and waterstones.

I still haven't had chance to tend to the wooden jointer plane yet, so to plane up the Sapele mahogany neck blank for this LP I used a power jointer to do the first few cuts and then the Stanley Bailey #4 plane my grandad had. I've dated this to 1940's - late 1950's, and it seems pretty well built. Besides the rust and gunk inside the body, it was in good condition so I completely disassembled it (inc. the frog), and went to work cleaning it out and using rust remover which worked a treat. After sharpening the blade, it glided across the mahogany to give a true and smooth surface on each side (although I'd still like to rough it up on the top with 100 grit sandpaper when gluing on the fretboard to hide the joint and provide some grip for the hide glue).

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The template for the LP neck is just 1/4" MDF from B&Q cut out with a jigsaw, edged with straight MDF and a router follower bit, and finally the curves were done on my tabletop drill press with a small drum sander bit I nicked from the dremel which was just the ticket.

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Speaking of planes, my other grandfather on my Mum's side showed me his cellar and said I could have whatever I liked since he'd like me to find a use for all his old tools. He couldn't remember what he had, but we were chuffed to find some clamps, vices, chisels, oilstones and a #3 Stanley plane in great condition!

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It's basically the same as the #4 yet thinner, but the nice thing about it is that it's so much lighter. I think I may end up using it for small jobs like headstocks after it's been re-honed.

Anyway back to the LP, here's the router thicknessing jig I made from MDF from the plans on PG's forum over christmas being put to work on a Khaya body blank. The first of the LP's I build will get this, whereas the rest will get more accurate body woods (genuine mahogany).

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The photo shows some honduran mahogany that has already been planed by the jig to 1 3/4" thick. Due to the limitations of router plunge depth, the side supports on the base of the jig are just over 1" thick up to half way and then they become over 2" thick for body blanks.
 
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Re: 1959 Les Paul replicas - build progress

You're so damn lucky dude, I'm jealous. Being a guitar/violin builder is my only true lifedream. We don't even have any garage or anywhere to do anything like that anywhere I live. Nor room to even friggin' mod or repair my amp... Nor the tools :( That looks cool man, good luck with the rest for sure!
 
Re: 1959 Les Paul replicas - build progress

Thanks Pierre - I've actually got no workspace either, but since my parents have left this room half finished (not painted or floored yet) for so long I cheekily claimed it for the time being as a workshop. I think next year when I'm living in a house instead of halls, I'll use a small pathway behind the house to work on guitars on with a small workmate bench since there's pretty much nowhere else to do it. If you don't use power tools though, luthery is a hell of a lot less messy (and an added bonus, less dangerous to fingers) and quite a bit cheaper - but harder. I'm trying to slowly use power tools less and less, to the extent where I've got my hands on a book published in 1881 on carpentry to improve my skills with hand tools. If you ever get any space in the future, try picking up some old hand planes and chisels etc from car boot sales as you can get them dirt cheap or even free if you meet the right people and I'll show you how to turn them into better tools than most of the mass produced junk you see today.
 
Re: 1959 Les Paul replicas - build progress

i really wish i had my own woodshop or even a work space... saddly i have to do all my work outside in the nicer weather.... being that i'm in Ontario Canada, i can work from mid April to end of September outside.. Thinking of starting a new tele project real soon. I will get some alder wood soon.
 
Re: 1959 Les Paul replicas - build progress

Well the body wood arrived today, all really nice pieces. This Korina is seriously light and resonant, I definately don't regret using this over Mahogany now for the body. I think I've found the perfect timber - it cuts like butter, planes incredibly fast and easily (it took under a minute to go from rough to properly surfaced as seen in the pic), sounds great, weighs less than Honduran Mahogany and looks great too. The maple was surfaced before I bought it, which should save a lot of time.

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3 Les Paul body/top's worth of timber there, which amounted to exactly £100 inc. delivery. I also got chance to take pictures of my hand planes again, I've bought a pair off ebay (No.4 1/2 and No.7 Stanleys), and got a cheap No.5 from Amazon.co.uk for £6! Although the original blade was poor, the rest of the plane is great and with a new Stanley blade for a few quid it's making lovely shavings.

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Re: 1959 Les Paul replicas - build progress

It's really nice of you to share these pictures. Thanks a lot.

I have tools to build a guitar (maybe I lack 2 or three small special ones) and I have been dreaming about a build lately. Nice tools btw. Can you tell us where you found the woods?

btw the part that I am most afraid when I consider building a guitar is the installation of the frets and the placement of the neck...

anyway, Good luck with the project bro. keep us posted :)
 
Re: 1959 Les Paul replicas - build progress

Thanks, the neck/body/top woods were all from SL Hardwoods, you should find their website by googling their name. I know what you mean about the frets and neck placement, they're probably the hardest areas to fix if you find out you've screwed them up once the guitar is assembled, but if you spend time making templates and get a pre-slotted fretboard, it shouldn't be an issue. I'll try to post pics at each stage of the build.
 
Re: 1959 Les Paul replicas - build progress

A pre-slotted freatboard can sure save you...
Thanks for the site!
 
Re: 1959 Les Paul replicas - build progress

Little update for those who are still following, I've actually been spending some time progressing with the guitars instead of just building jigs or acquiring tools for them lately, and have some pics to show.

Clamping up and gluing the two pieces of Korina for the back:

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Perfect joint with invisible seam - hard as hell to do with a hand plane if you've never tried it before, but it looks the business and is necessary when using hide glue:

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Marking out where im going to route the cavities, there's still a bit of drum sanding necessary:

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I made this curved rail jig out of MDF for routing the truss rod channel, here's it attached to the neck with double sided tape, I also fixed it with screws to parts of the neck that would be cut off later:

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Routing out the curved 3/16" wide channel:

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Cutting out the anchor slot with a sharp chisel:

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Sheathless truss rod, with brass adjusting nut, on top of some flamey hard rock maple I'm using for the top:

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Re: 1959 Les Paul replicas - build progress

Installing the maple fillet for the truss rod, with hide glue:

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Today I built a jig for the Safe-T-Planer drill press attachment to thickness fretboards with and also to make those truss rod fillets exactly 3/16" thick - works a treat!

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That's one of the 2 matched Cocobolo fretboards I'll be using on my doubleneck 6/12 Strat project, hopefully that should get going soon as well.
 
Re: 1959 Les Paul replicas - build progress

This is...by far....the coolest thread I have read in a VERY long time!
 
Re: 1959 Les Paul replicas - build progress

Very cool work you are doing!

i've been wanting to make a router jig like that for vintage truss rods for a long time.. only i have ever little details on what the curve radius should be and how deep to go...
 
Re: 1959 Les Paul replicas - build progress

Way, way cool project!!

Just out of curiosity... why are you calling it a "1959 Les Paul replica?"
 
Re: 1959 Les Paul replicas - build progress

Keep it coming. This is wonderful!! You should do one of these for your Strat and have it vaulted!!
 
Re: 1959 Les Paul replicas - build progress

Great thread for sure, it's very awesome to see the building process from the start. Right now i'm in the process of finishing on a ash tele body and i'm already thinking about future projects....hopefully someday i'll be to the level of being able to 'make everything' from scratch like you are doing. Definately keep us posted, i look foreward to seeing the final product.
 
Re: 1959 Les Paul replicas - build progress

If you do a lot of planing/spokeshaving, get a set of diamond stones from dmt. You can get a set of 3 or 4 of them. They are so much better than oil or water stones, and they never get curved in the middle. Seriously, they make sharpening those blades so much easier!
 
Re: 1959 Les Paul replicas - build progress

If I'm not much mistaken, you routed the back cavity on what would be the top of a righty guitar. Is it a lefty build?
 
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