Aluminum Guitar

[Bodaggit23]

I'm a CNC Programmer for a company that builds packaging equipment for the pharmaceutical industry, mainly, and I have access to some pretty state of the art software and machinery.We create all our parts on Mazak CNC's. We currently have 6 mills and one lathe.


All our packaging machines are created as 3D models in Pro/Engineer, and not only do I create programs for the CNC mills, I've dabbled in modeling plenty over the last 7 years that I've worked there. I'm no engineer, but I can measure stuff and create it in 3D, and subsequently create the code required to make the parts on the mills. Sweet.


So, I decided some time ago to create an aluminum body guitar based on my white HM.


I started modeling this a couple years ago, in hopes of stealing the neck off my white HM, but I've had a change of heart, and a newfound love for my HM's, so this won't be happening.


Anyway, I've decided to follow through with this idea, but I don't think it'll be an HM because as you know, "extra" necks are hard to come by.


So, I'm scouring ebay and Craigslist for a Jackson PS-2 or PS-3/T neck, and maybe a trashed Jackson body I can measure to make this guitar a reality.


I'll gladly take suggestions on an alternate neck or body, especially based on availability. I just like the PS necks. ;D


Anyway, I basically started from scratch tonight, modeling the guitar, and since I have no other body to base the model on, I used the HM again, just for practice. Some of the contours are a bit tricky to create, but I got them, however it may be hard to see in the pic.


The guitar is modeled as one piece right now, but will be split in half, and each half will be hollowed out for weight reduction.


The top half will have blind threaded holes from the backside so you'll just see a solid top. I'll use dowel pins to align the halves.


We make gear casings this way, and I've never seen an aluminum guitar made like this so I'll give it a go.


Ok, enough story, and this make take a while to finish, but I'm gonna do it!


I always struggled, whether to take the easy way out and use a fixed bridge, or go all out and give her a trem. Still undecided, but I have lots to do before I need to decide.


Here's some pics of the model, whole and the two halves, not pocketed out yet.


The first picture of the model has a scale .jpeg decal of my white HM applied. Only the outer contours and neck pocket is done so far.


Model with .jped added as a decal. I just "traced" around the picture to get the body shape. The picture also shows the shadows of the cutouts. Very helpful.



Top of the model



Back of the model



Two halves

[lbeast]

Bo,

If you need an HM neck just for measurements I could mail you a spare '88 I have that is slightly twisted. I'll need your mailing address and a promise you'll return it when done. Send me a private e-mail and we'll discuss if you like.

I'll pay for the S&H to you if you'll pay the return S&H. Don't know if the twist will hamper your measuring process. You're more than welcome to play with the truss rod to get the neck as straight as possible for your measuring.

I'd love to see you build it with a tremolo. You can find old Kahler Spyders & Steelers on eBay from time to time. A new Ibanez Lo Pro or a FR Pro tremolo would be a good substitute for the Kahler Spyder or Steeler. Just a suggestion.

lbeast

[Bodaggit23]

That's an amazing offer, thanks!

Still, I'll need a neck to finish the project, and I think I should look for a cheaper, more readily available alternative to the HM neck. Who knows when another neck will come for sale?

Speaking of "For Sale", would you consider selling me that neck you have?

[heem6]

Hey Bo,
I was gonna make you the same offer but with an HM body if you'd like to borrow it for reference. I have two spare bodies sitting around and would also ship out if you promise to ship back when you're done.

One of us will have to measure a neck heel for you. Traditional Strats are 2 3/16" wide I believe, while Jacksons are 2 1/4".

Very cool project! email me at [e-mail] if you're interested.

[lbeast]

Bo,

Yeah, didn't intend to sell it since I still have the original body it goes to. But, your welcome to use it as a reference.

If you want to buy one, they are on eBay a few times a year or you could place a want ad in eBay. Don't know if anyone looks at the wanted ad section of eBay, but it is available.

This sounds like a project that may take some time anyway. You should make the neck out of aluminum as well.

[heem6]

Anybody remember the old Kramer Aluminum neck guitars?

[Bodaggit23]

Feb 26, 2010 12:59:29 GMT -5 lbeast said:

This sounds like a project that may take some time anyway. You should make the neck out of aluminum as well.

Gotcha. No problem.

I've thought about it a bit more and I've decided that this first "attempt" should be scaled down a bit, and not have me investing hundreds of dollars on extra parts and possible failure with a trem.

I've decided to buy a cheaper guitar from a pawn shop, and use it as a surrogate. That way I have all the necessary hardware, and a body to measure. Keeping it simple this first go around.

I can get it done much faster this way also, and I'll have valued experience when I decide to make another, higher end version.

[lbeast]

I here ya. Sounds like you want to get your first attempt started right away, then take your time with the next one. I understand your eagerness. Well the offer still stands for the borrowing.

[Bodaggit23]

I certainly appreciate the offers guys, but yeah, I want to get rockin on this thing! Once I get a mindset on something, I get a bit obsessed until it's done.

In theory it should work out good, but you know how engineering theories go sometimes...

The main issue, is the two piece body, and the depths of the trem pocket on the backside, where the springs attach.

I won't know until I get it modeled further. And before I can do that, I need a donor guitar. My F-50 neck would be perfect... ;D

[Bodaggit23]

Getting close guys. I'm woodshedding this thing. ;D

Neck pocket Test turned out perfect first try. I'll add rounds to the heel when I do finishing touches.









Modeled the Super 3, Bridge, and Tailstop, cut pickup pockets, and added a String. LOL

Did some detail work on the headstock just because...

There is an issue with the pocket, as there's about 3/16" gap between the 24th fret and the string. I'll work on that later.

[lbeast]

Dude!!!!!!!!!!!!!!!!!!!!!!!!!!

That pocket is dead nuts!

The only thing I would be worried about is how much is this body gonna weigh when it's done? Are you planning to hollow it out somehow to lessen the weight? A solid block of aluminum I would think is going to weigh alot.

Just Curious what your game plan is on this. ;D

[Bodaggit23]

Yes sir.

Two sheets of 3/4" MIC 6 ground aluminum plate, pocketed out and pinned together.

Once I get the neck pocket "shimmed" in the model, that's the next step. Cut 'er in half and start hollowing.

Well, I ran my pickup pocket, bridge, and talistop TEST piece, and all is good. Taking your time measuring everything accurately sure pays off!

Here's the Pickup Pocket/Bridge/Tailstop TEST.

[lbeast]

[glow=red,2,300][shadow=red,left,300]I want a CNC router. [/shadow][/glow]

[heem6]

Holy crap this is a cool project! I hope you realize you're making us all envious! Can't wait to hear what it sounds like when finished! It sure looks cool.

Looks like you're doing a great job. Just like a guitar tech once told me, "Measure twice, cut once."

[Bodaggit23]

CNC is definitely the way to go. Luckily, I have access to the software that ices the proverbial cake. ;D

From now on, until I start making chips, it will just be pics of the rendered model, as all the critical features are proven.

I got the neck issue straightened out, but I need the assistance of an engineer to help me solve an issue with the neck pocket.

I got the neck straight, but now there's a .06" gap under the neck that I'd rather not shim, so I need help filling the wedge shaped void in the tapered pocket. I thought I could figure it out, but hey, I'm a high school grad...

Here's a before pic, with the neck flat in the pocket, which created over .25" of action at the 24th fret. Even after I lowered the bridge all the way flush, the action was still huge.



Here's a shot showing the perfect action, but the .06" wedge shaped gap I wan to fill in so the neck sits true in the pocket. Looks like it would be easy to fill in, right? LOL