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Making my first flamenco guitar "El Xiprer"   You are logged in as Guest
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Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

Making my first flamenco guitar &quo... 

Firstly let me say hello to everyone – I’ve been reading posts on this forum for a while and learning lots and am now in the position to share. I’m a guitar player of 50+ years and a guitar maker of 14 years. My main love in playing steel stringed guitars but I’ve liked flamenco guitars from when I was a teenager. Back in 2013 I helped a friend complete his project of making a Flamenco Blanca guitar where he had completed the top and back and I finished the rest. He was using the Roy Courtnall book and the Santos Hernadez plans in it.

Since then I’ve wanted to make one of my own – my first nylon string guitar and later in 2013 I had to have a Lawson’s Cypress tree in my front garden cut down:



Having discovered that Lawson’s Cypress is a tonewood – Port Orford Cedar – similar to Spanish Cypress used for Flamenco Blanca guitars I had the contractors cut the main trunk into sections that could be cut into instruments sets:



The tree rings confirmed that the tree had been planted in the mid 1930’s when the house was built. In 2014 my friend and classical guitar maker Colin Symonds kindly helped me process “The Tree” – here he is in the process:



And here’s me:



And here’s the result:



That was the birth of my idea to make a Flamenco Blanca guitar using as much wood as possible from “The Tree” and my research began. Last October with my wife and youngest daughter I went to Barcelona for a few days where I did some more research at a luthier’s shop there and decided that the guitar would be called “El Xiprer” – Catalan for “The Cypress Tree”:





The guitar is now strung up in the white but I’ll present the “making” here in stages over the next week or so in the present tense which will then catch up with the finishing process. Port Orford Cedar was used for the top, back, sides, neck, linings and bracing with figured Bog Oak for the fingerboard, Coyote Wood (Platymiscium polystachium) for the bindings, end graft, heelcap and headplates, and Bog Oak for the bridge. Purflings are black/ pear/ black. It will have a 650mm scale length and geared Peghed tuners. Having inherited the Solara and made a bending form for a Santos Hernandez guitar from the previous project, this is the shape I will use for “El Xiprer”, but the bracing and everything else will be my design.

The first job is to join the thicknessed top and back using hot hide glue and the “tent” method:





The channel for the inlaid backstrip is routed out:





The backstrip is then glued in consisting of a Coyote wood central strip flanked each side with black/ pear / black and a rope purfling:



When the glue is dry the centre strip is scraped and sanded flush and the back cut close to final shape:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 9:57:13
 
Anders Eliasson

Posts: 5780
Joined: Oct. 18 2006
 

RE: Making my first flamenco guitar ... (in reply to Dave White

Now thats cool.
Making guitars from a tree from your own garden.

Have you heard about this Canadian violin-cello maker, that bought a piece of land because he liked the trees on it and has used them for all his instruments.
I cant remember his name, but he´s well known. Big beard and live out on one of these fiddle tune Islands near Newfoundland.

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  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 16:51:30
 
Leñador

Posts: 5237
Joined: Jun. 8 2012
From: Los Angeles

RE: Making my first flamenco guitar ... (in reply to Dave White

Welcome aboard and very cool!!
Did you have to kiln dry it??

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  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 17:04:42
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

Anders - Yes, cool and very exciting. I haven't heard of that maker but can empathise - I'll have to work harder on the beard though !

Lenador - No, just air dried/seasoned in my workshop. Colin took some of the wood and he's more scientific than me. He stickered and weighed it daily until it stabilised and that only took a couple of months. I remember talking to Shane Neifer who harvested Lutz Spruce tonewood in British Colombia, Canada and his process of stickering with a fan circulating air around it took around 6 weeks until the wood was stable and usable

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 17:27:52
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to Dave White

About drying woods..

Anyone baking/roasting them already or is it something that for some reason wouldn't work with acoustic instruments?

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  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 17:33:30
 
El Kiko

Posts: 2697
Joined: Jun. 7 2010
From: The South Ireland

RE: Making my first flamenco guitar ... (in reply to Dave White

What design are you using as a base to construct from ... and scale length etc...?
dont you have to leave the wood to season a while before construction time ?


I assume you can get more than one guitar out of a wole tree that size ... and maybe a matching cejilla..or 2

but yeah , great project

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  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 17:37:28
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Sr. Martins

Sr. Martins - I like my wood naturally air dried and seasoned. Currently "torrefication" is apparently "the new black" for guitar tops which fits your baking/roasting description.

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 18:17:43
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to Dave White

quote:

Currently "torrefication" is apparently "the new black" for guitar tops which fits your baking/roasting description.


But is anyone doing it already on classical/flamenco guitars? I've only seen it on electric.

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  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 18:26:09
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to El Kiko

Scale length is 650mm, body shape is the Santez Hernandez Flamenco in Roy Courtnall's book, bracing will be my own design. Yes the wood is seasoned and ready for use and there's lots of wood left for other stringed instruments - guitars, harp guitars, dulcimers, mandolins, ukuleles, hurdy gurdys - some of which are in the pipeline. Colin beat me to it and made this "English" guitar with some of the top wood he took combined with English Walnut back sides, Cherry neck and Bog oak fingerboard, bridge and binding:





Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 18:29:19
 
Flamingrae

 

Posts: 220
Joined: May 19 2009
 

RE: Making my first flamenco guitar ... (in reply to Dave White

Great stuff - glad I'm not the only nut case who does this. Local firm came to chop down a sycamore in my back garden as it was getting a bit on the big side. I got them to leave a good big clean trunk. I quartered it and it's been drying out the back for about two/three years. Just got some beefy bandsaw blades and will have a slice up soon. It has spalted though - see if I can get a bit up. Also, local council came and sent the men round to dispose of a cherry tree that fallen down. I bought the guys a few tins of beer and they happily obliged with another trunk. It would have gone for pulping otherwise.
  REPORT THIS POST AS INAPPROPRIATE |  Date Feb. 29 2016 23:18:44
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Sr. Martins

It's the latest marketing buzz word for steel string guitars but you'll have to ask the flamenco luthiers here about its impact on the flamenco/classical world.

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 1 2016 7:42:34
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

Next job is to make and fit the rosette. Firstly a ring of Coyote wood is cut using my circle cutting jig:





The rosette channel is cut in the top using a spiral downcut bit to fit the Coyote wood ring together with inner and outer black / pear / black purflings:



These are then glued into the rosette channel:



The luthier giveth and the luthier taketh away – next a 9mm ring is routed in the centre of the rosette:





A central strip of two rope purflings with inner and outer black / pear / black is then glued in:



When the glue has dried the rosette is scraped and sanded flush. The 86mm diameter soundhole is then routed out and the top cut close to final shape:





Images are resized automatically to a maximum width of 800px

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Dave White
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  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 1 2016 7:46:01
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

It’s time to start the top bracing. The guitar will have six fan braces, the outer two of which will pass through the harmonic bar and upper transverse brace and will lock with the top of the neck extension under the fingerboard. These two fan braces are glued on first using hot hide glue:





The soundhole support – a 1.9mm thick cross grain piece of Port Orford Cedar with a 92mm diameter central hole – is then glued in using hot hide glue:



The upper transverse brace is notched to accept the outer fan braces and is glued on using hot hide glue. This brace has a flat profile:



The harmonic bar is radiused to 13’ notched to accept the outer fan braces and is then glued on using hot hide glue:



The next two fan braces are glued on:



The final two fan braces are then glued in:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 7:40:11
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to Dave White

Is that a cypress top?

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  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 12:32:59
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Sr. Martins

Yes - Top, back, sides, neck, bracing and linings on "El Xiprer" are all Port Orford Cedar (Lawson's Cypress - Chamaecyparis lawsoniana) ,from the tree in my garden.

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 13:08:23
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to Dave White

Has it ever been done before? I thought it would implode or something..

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  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 13:21:53
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Sr. Martins

I'd be very surprised if it hasn't been used for a flamenco guitar top before.

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 14:49:37
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to Dave White

If it works and sounds good, that's what matters.

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"Ya no me conoce el sol, porque yo duermo de dia"
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 14:58:04
 
Anders Eliasson

Posts: 5780
Joined: Oct. 18 2006
 

RE: Making my first flamenco guitar ... (in reply to Dave White

Loads of guitars have been made with port oxford cedar as soundboard.

You can build with whatever. It wont implode if its thick enough and/or the little sticks are strong enough.
Anyone in for a poplar blanca? Here in Spain we have some genetically changed poplar in plantations. Its for making paper. Its really soft and white. It disappears in no time when burning.
Very much Espanish, muy flamenco. Special price for you hermano amigo.

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  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 15:41:59
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to Anders Eliasson

quote:

Very much Espanish, muy flamenco. Special price for you hermano amigo.


Grassy ass senior, I am happy with the pieces of wood I have.

The only thing I don't like is the finish on the neck, I've tried a few things but it's still sticky. I would love to make it feel like my Charvel which is practically bare wood with Truoil as a pore filler.

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  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 15:51:30
 
printer2

 

Posts: 54
Joined: Sep. 19 2015
 

RE: Making my first flamenco guitar ... (in reply to Sr. Martins

quote:

But is anyone doing it already on classical/flamenco guitars? I've only seen it on electric.


Not made as a flamenco but as a small light weight nylon stringed guitar. Top and back is baked pine, sides were not. Walnut fretboard and EIR bridge. Spruce neck, can't remember if I baked it. Posted a picture of it a while back.



Nice looking wood, like the rosette. Can't wait to see more.
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 2 2016 22:33:39
 
Sr. Martins

Posts: 3077
Joined: Apr. 4 2011
 

RE: Making my first flamenco guitar ... (in reply to printer2

quote:

Not made as a flamenco but as a small light weight nylon stringed guitar. Top and back is baked pine, sides were not. Walnut fretboard and EIR bridge. Spruce neck, can't remember if I baked it. Posted a picture of it a while back.


Could you post a link to the pics, please?

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  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 3 2016 1:11:51
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

The top braves will be carved and shaped later. Now for the back. The cross grain centre strip pieces are glued on the back using hot hide glue:



When the glue has dried the strips are rounded over on the edges and the first ladder brace glued onto the back using hot hide glue. This brace has been profiled to a 10’ radius:



The middle ladder brace is glued in:



Finally the upper bout ladder brace is glued in:



I’m going to fit a Coyote wood “porthole” soundport in the bass side upper bout. First job is to cut a 42mm diameter hole in the thicknessed Port Orford Cedar side to take the “porthole”:





A Port Orford Cedar blank fills this hole whilst the side is bent. An identical sized Coyote Wood blank was cut at the same time to form this part of the “porthole”:



The side is then bent in the Fox style bending machine:



The two parts of the Coyote wood “porthole” are glued together using hot hide glue:



The inner porthole is routed out using the circle cutting jig:







The “porthole” is then glued into the bass side hole using hot hide glue:



The treble side is bent in the Fox bender and the two sides trimmed and clamped in the assembled Solera:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 3 2016 8:54:44
 
printer2

 

Posts: 54
Joined: Sep. 19 2015
 

RE: Making my first flamenco guitar ... (in reply to Sr. Martins

quote:

quote:

Not made as a flamenco but as a small light weight nylon stringed guitar. Top and back is baked pine, sides were not. Walnut fretboard and EIR bridge. Spruce neck, can't remember if I baked it. Posted a picture of it a while back.


Could you post a link to the pics, please?


http://www.foroflamenco.com/tm.asp?m=282057&appid=&p=&mpage=1&key=&tmode=&smode=&s=#282112

quote:

  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 3 2016 10:58:23
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

The Port Orford Cedar neck blank is then cut to form the headstock and top fingerboard supports and a separate section cut for the bottom part of the heel:



The two pieces are glued using hot hide glue:



The channel for the central carbon fibre bar is routed:



The bar will be capped with a Port Orford cedar strip:



The bar and cap are glued in using fish glue:



The channels for the smaller outer two carbon fibre bars are routed:



These bars will also be capped with a Port Orford Cedar strips:



The bars and caps are glued in using fish glue:



The side slots are then cut:



Here are the finished slots. Each side will be held in place by two wedges:



The heel is cut on the bandsaw:



Then the heel is shaped:



The sides of the “headblock” section of the neck are sloped to make the section that fits onto the back narrower. The top of the “headblock” is rebated to the depth of the top and slots cut to take the outer two fan braces. Here’s how the top fits:



The sides are then test fitted with the wedges inserted dry:



The Coyote wood headstock veneers together with black/ pear/ black veneers are glued to the top and back of the headstock using fish glue:





The front headstock veneer will have a central insert matching the centre of the rosette - two rope purflings with inner and outer black / pear / black purflings. The channel is routed with a 9mm bit and this jig:



The headstock shape will have a central “point” so the inlay matches this. The channel is shaped, the outer purflings mitred and everything tested and then glued in:



Next the headstock is rough shaped and the positions for the pegs marked. These are drilled with a 9mm drill to be reamed later:



Initial carving of the neck is now done as it will be easier than with the neck attached. Fine tuning will come when the fingerboard is attached:



The peg holes are then reamed using a banjo 5th tuner reamer – one of the few occasions where banjo making comes in handy elsewhere:



Here’s the finished headstock. As “El Xiprer” has a Catalonian influence the shape is a tip of the cap to Antoni Gaudi:





Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 4 2016 7:47:26
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

The Lime tailblock has the central Coyote Wood part of the end-graft glued on using hot hide glue:



The bass side is glued onto the tailblock together with black/ pear / black and a rope purfling using hot hide glue. The completed end-graft will match the back strip:



The treble side is glued on in a similar way:



Now for an exciting bit – the neck and sides are joined with wedges glued using hot hide glue to the neck block but not to the sides in the Solera that has the neck back angle incorporated:



The sides are shaped to fit the curve of the back and the position of the back braces marked on the rim:



The back Port Orford Cedar reverse kerfed linings are then glued on using fish glue:



The sides are shaped to fit the curve of the top and the position of the top braces marked on the rim. The Port Orford Cedar reverse kerfed linings are then glued on using fish glue:



The final three top braces I alluded to earlier are glued on:



The braces are carved and the top “voiced” and signed:





The rim/neck assembly is then glued onto the top in the Solera using fish glue:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 5 2016 9:44:22
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

The side brace supports for the top braces are glued in using hot hide glue – the back side brace supports have already been glued in:



The back braces are carved and the back “voiced”:



Next a caul for clamping the bridge is made that fits over the fan braces:



Fish glue is then put on the back linings and the back glued on:





Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 6 2016 8:59:24
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

Then it’s out with the binding jig to cut the binding channels. The channels are first cut on the top the width of the bindings and the depth of the bindings plus side purflings. Some scrap pieces of the side purfling are stuck onto the top at the end graft with double-sided tape. The router rides on these to cut the rest of the binding channel. The channels are tidied up with a chisel and the side purflings can be mitred:



The binding channels need to be cut by hand where the body joins the neck:



Then the back binding channels were cut using the same process:


Using a sharp saw and chisel the binding channels are continued over the heel cap:



The top purfling channels are then cut:



The top bindings with top and side purflings are glued on using fish glue:



The back purfling channels are cut. This is more complicated than the top as the back purflings have to be mitred with the purflings on each side of the back strip:



The back bindings with back and side purflings are glued on using fish glue:



When the glue has dried the tape is removed and it’s into the Troji to scrape down the bindings:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 7 2016 9:21:37
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

A Coyote Wood heel cap together with black/ pear/ black veneers to match the side purflings is glued on using hot hide glue:



The Bog Oak fingerboard is marked and the fret slots cut in this jig:



The fingerboard is then tapered and the neck checked to see that it has been left slightly oversize to fit the fretboard. The end of the fingerboard is then cut to match the soundhole using this jig:





The Bog Oak fingerboard is then clamped onto the neck and 2mm holes drilled through frets for cocktail sticks to be inserted to hold it in place while gluing. A straight edge is put along the fretboard and the gap between it and the top is measured at the saddle position. The fingerboard is thicknessed until the gap is around 2mm:



The fingerboard is 5.6mm thick and there will be enough wriggle room to straighten the fingerboard, build in relief and have the string height at around 8mm off the soundboard with a 2.75mm action at the 12th fret. The fingerboard is glued on using fish glue and the cocktail sticks removed when the clamps are tightened:



The neck is shaped to meet the fingerboard edges and then the fingerboard is levelled. A small amount of relief is then shaped in with a slight drop away towards the bass side from fret 9 upwards. I’m hoping that the carbon fibre in the neck will keep things stable without too much back bow from fretting compression. The string tension should then pull a small degree of relief in the neck – that’s the plan. If not I’ll take the frets off and shape more relief into the fingerboard:



Time to install the stainless steel frets:



The frets above the body are pressed in using these cauls:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 9 2016 18:01:53
 
Dave White

 

Posts: 36
Joined: Feb. 29 2016
From: Buckinghamshire, UK

RE: Making my first flamenco guitar ... (in reply to Dave White

Soundports are not to everyone's taste. Well, you can choose. I decided to make a stopper for the “Porthole Soundport” as I have done on other guitars so you can chose to play “El Xiprer” with the soundport open or closed. Three rings of Coyote Wood are glued together using hot hide glue – the outer cover and two inserts:



The central hole is reamed to fit an ebony bridge pin that is glued in using superglue:



The bridge pin is trimmed flush with the inside and a ring of cork glued around the inner rim:



Ported:



Unported:



Images are resized automatically to a maximum width of 800px

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Dave White
De Faoite Stringed Instruments
  REPORT THIS POST AS INAPPROPRIATE |  Date Mar. 10 2016 7:47:47
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