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Introduction

 

Explorer Intro- 1 - 

 

Warning 

These instructions assume that you are familiar with the safe operation and use of woodworking machinery 

and woodworking tools, and understand the techniques used to assemble this project. If you do not qualify 

for both of these criteria, STOP building this project for your own safety. Read and understand the owner’s 

manual for the machinery you intend to use, take a woodworking class or visit your local library for more 

information. Woodworking machinery and tools are inherently dangerous because they use sharp edges 

that can and will cause serious personal injury including amputation and death. Do not underestimate the 

ability of these tools and machinery to cause injury. Never operate any tool without all guards in place and 

always wear approved safety glasses. For your own safety, please heed this warning. 

 

 

Warning 

Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses are 

not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American 

National Standards Institute (ANSI). Because there are various ways to cut and join wood, you can make 

substitutions for the methods stated in this manual. We try to suggest the easiest methods possible. 

However, only you know your skills with each piece of machinery. Never compromise your safety by using 

a cutting method with which you are not comfortable. Instead, find an alternative approach that will yield 

the same result. 

 

WARNING 

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains 
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.  
Some examples of these chemicals are: 

 

Lead from lead-based paints. 

 

Crystalline silica from bricks, cement, and other masonry products.  

 

Arsenic and chromium from chemically treated lumber. 

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your 
exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, 
such as those dust masks that are specially designed to filter out microscopic particles.

 

 

 

 

Summary of Contents for Explorer Guitar Kit

Page 1: ...Explorer Guitar Kit Assembly Instructions WWW www byoguitar com...

Page 2: ...ertain the safety glasses you wear meet the appropriate standards of the American National Standards Institute ANSI Because there are various ways to cut and join wood you can make substitutions for t...

Page 3: ...ridge assembly Figure 2 4 1 2 2 5 Miscellaneous Fit Checks 3 2 5 1 Fit check of the back cavity Cover Fig 2 5 1 1 3 2 5 2 Output Jack 3 2 5 3 Check Strap Pins 3 2 5 4 Check Tuner Alignment 3 3 Finish...

Page 4: ...tall the Pickguard and Selector Switch 6 4 3 Installation of the Bridge Components 7 4 3 1 Installing the Bridge 7 4 3 2 Installing the Tailpiece 7 4 4 Installing the Nut 7 4 5 Installing the Tuners T...

Page 5: ...shing materials especially if they have to be ordered will allow expedite your guitar project We carry a full line of finishing products that give you the beautiful finish you are looking for whether...

Page 6: ...piece parts are included If you customized your order ex different tuners ensure that these parts are accounted for Please contact BYOGuitar if there are any discrepancies Explorer Material List Item...

Page 7: ...matic bridge 2 posts Explorer stop tail 6 1 harness w 3 potentiometers Explorer Wiring harness 7 1 stop 2 posts Bridge assembly 8 1 tone 2 volume Explorer knobs 9 6 Tuning Pegs 6 Washers 6 Nuts 6 scr...

Page 8: ...11 Jack w plate 4 mounting screws Output Jack assembly note jack is prewired to harness 12 2 Holders 2 plastic washers 2 screws 1 Strap Holder materials 13 1 String Nut guide String Nut 14 6 strings...

Page 9: ...ools materials required Drill drill bits 1 2 Phillips screwdriver Soldering iron solder Masking painters tape Finishing painting material Sand paper 220 320 grit Guitar strap Soap or candle Feeler gau...

Page 10: ...sh has been applied and completely dried In this section all of the components are installed internal wiring connected and strings attached your guitar will ready to go Section 5 Setup in this section...

Page 11: ...nd that all screw holes have been drilled 2 1 Fit check the Neck to the Body Gently insert the Neck into the neck cavity on the Body the fit should be snug to ensure proper alignment when these pieces...

Page 12: ...orer guitar kit comes with a wiring harness that is ready for installation during assembly of your guitar Section 4 Check the harness to ensure that all wiring remains solidly soldered to each compone...

Page 13: ...e Strap Pins item 12 on the material list reference Figure 2 0 If the holes are pre drilled skip to 2 5 4 1 Mark the rear Strap Pin hole so that it is approximately 7 from the bottom of the Body and t...

Page 14: ...he application of several finish types including 1 Solid color 2 Pigmented translucent gel stain or alcohol dye 3 Penetrating stain or water based dye The guitar body was sanded at the factory and coa...

Page 15: ...e body and neck 2 Apply grain filler if desired 3 Apply 2 coats of sand and sealer 4 Sand to 320 grit 5 Apply stain or dye 6 Apply clear top coats 7 Buff finish 3 1 3 Penetrating Stain or water based...

Page 16: ...mended We recommend using Behlen PORE O PAC grain filler For most finishes use natural colored filler The dyes used in darker fillers may over time find their way through the color coat Apply the fill...

Page 17: ...h have been applied DO NOT sand through the finish be careful on the edges Use a tack cloth to remove sanding residue Apply more finish sanding between coats until the finish is the desired thickness...

Page 18: ...Installation of the Bridge Components 7 4 3 1 Installing the Bridge 7 4 3 2 Installing the Tailpiece 7 4 4 Installing the Nut 7 4 5 Installing the Tuners Truss Rod Cover Figure 4 5 1 8 4 5 1 Installi...

Page 19: ...e location to determine the neck placement DO NOT simply position the neck so the heel of the neck is at the back of the pickup cavity Typically the neck doesn t reach the back of the cavity and shoul...

Page 20: ...he last thing to check is the neck angle Figure 4 1 3 1 If the angle is not correct you won t be able to get the correct action With the neck in the pocket place a straight edge on the frets Push the...

Page 21: ...ing the Wiring Harness As noted the wiring harness comes assembled and only requires to be run through various tunnels prior to being connected to other components Figure 4 2 1 1 details the Body vari...

Page 22: ...own in Figure 4 2 2 1 where the Neck pickup has a smaller taper than the Bridge pickup Also note that the pickups are mounted with the small dimension of the taper pointed toward the neck 1 Run the sh...

Page 23: ...kguard and mount the pickguard on the Body Use caution when compressing the switch wires to fit into the Switch pocket to ensure no wires are broken Before starting ensure that the clear protective fi...

Page 24: ...djustment screws into the inserts 4 Place the bridge onto the adjustment screws with the individual string adjustment screws facing the neck Figure 4 3 1 4 3 2 Installing the Tailpiece 1 Remove the Ta...

Page 25: ...P3v bxwE Although the video addresses restringing a guitar the principles and techniques will help you string your guitar as well as provide a visual for the stringing of your guitar 1 Carefully uncoi...

Page 26: ...ht 3 Adjusting the Pickup heights 4 Adjusting the Intonation These adjustments will provide preliminary settings from which you can fine tune the sounds to your individual playing style As with previo...

Page 27: ...backward too much and the strings will buzz on the frets and loosening it will cause it to bow forward giving more relief CAUTION If you find that the truss rod is very difficult to turn then stop It...

Page 28: ...rst string to the sixth string The question here is how high to make the bridge This is personal choice Adjusting saddle height is very easy on the Explorer guitar Since the bridge can only be adjuste...

Page 29: ...inist ruler measure the distance from the top of the pole to the bottom of the 1st string note bass measurement 1 3 Repeat 1 1 1 2 on the 6th string note the treble measurement 2 Neck Pickup repeat st...

Page 30: ...w the strings to warm up Metal expands when warm and contracts when cool After you ve played a few riffs you can then do your final tuning 2 Wipe the strings neck and bridge with a lint free cloth aft...

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