Stewart MacDonald 5295 Page 1 Assembly Instructions Manual Download

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Dreadnought

Acoustic Guitar Kit

#5295 Assembly Instructions

www.stewmac.com

Summary of Contents for 5295

Page 1: ...Dreadnought Acoustic Guitar Kit 5295 Assembly Instructions www stewmac com ...

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Page 3: ...ng the fretboard side dots 20 Installing the frets 20 Installing the fretboard 21 Neck shaping and fitting Shaping the neck 22 Fitting the heel cap 22 Understanding the neck joint 23 The neck heel sets the neck angle 23 Fitting the neck to the body 23 Neck adjustment side to side 24 Neck adjustment tilt the neck back 24 Neck adjustment tilt the neck up 25 Tightening the dovetail joint 26 Installin...

Page 4: ... will need Tools Electric hand drill Coping saw Center punch or awl Glue brushes 4167 6 Steel rule 4894 1 2 Chisel 1 4 and 3 8 diameter brad point bit in 0339 set File set 0842 Mini rasp set 3064 Nut slotting files 4541 4542 4543 and 4544 are suggested for the kit Fret Leveler 0862 Dressing stick 1826 Fret cutter 0619 Fret hammer 4895 24 Straightedge 3799 Radius gauge set 5432 020 gauged saw 3598 ...

Page 5: ...erringbone rosette 3 pieces 17 Rosewood peghead overlay veneer Kit parts list 18 Maple bridge plate stock 19 Binding 2 20 Back brace set 9 pieces 21 Reinforcement strips 3 22 Hot Rod truss rod 23 End trim heel cap 24 White pearl dots 8 25 White side dot material 26 Ebony bridge 27 Bone saddle blank 28 Bone nut blank 29 Bridge pins 6 cream or black 30 Endpin cream or black 31 Shim stock not in bolt...

Page 6: ... fairly steep 5 angle to match the arch of the back the open top of the neck block has a shallower 1 1 2 taper Trace around the neck block onto the cardboard and use a sharp knife to cut along that line through the first layer of cardboard Don t cut the edge where the block meets the guitar sides This allows you to compress the cardboard downward to make clearance for the 1 1 2 taper of the neck b...

Page 7: ...supporting the guitar sides Make a U shaped waist clamp from 3 4 thick plywood using the waist clamp measurements illustrated The purpose of the waist clamp is to hold the guitar s waist tight to the inner cardboard mold maintaining a constant shape until the back is glued on Use a file to round the two inner edges of the waist clamp to remove edges and protect the guitar sides To start out instal...

Page 8: ...ing glue up Disassemble trim the lin ings glue them into place with Titebond check the 1 32 clearance and reclamp Let the glue dry for 4 hours Install the kerfing strips on the back edge of the side assembly in the same manner Installing kerfed linings Squaring the neck block and tailblock Although they work quite well the waist clamp and card board inner body mold still allow some movement Handle...

Page 9: ...ding the neck block and the front shoulder area first Work around the sides to the tailblock moving the pivot point frequently until the sandpaper begins grazing the white pencil marks on the top edge of the sides It s easy to oversand the sides and the kerfed linings leaving the neck block or tailblock higher than the sides and causing a hump in that area later Keep this in mind and give the bloc...

Page 10: ...ng pattern pencil the soundboard bracing pattern pictured on the inside surface of the soundboard cut small holes in the pattern at the corners and intersec tions of the braces lay the pattern on the soundboard transfer the hole positions in pencil and connect the dots on the soundboard when the blueprint is lifted away The patternMUSTbecorrectlycenteredalongthesoundboard s centerseam withthesound...

Page 11: ...es File off each pointed end of the bridge plate so that it can slide forward as it tucks under the X braces Prepare a wooden clamping While the braces are accessible prepare a bridge clamping caulandashoulderbracecaulthatwillbeusedinthe Install ingtheneck and Installingthebridge sections Thebridge caul illustrated is 7 1 2 x 1 3 4 x 3 4 It must be relieved to contact the bridge plate and the soun...

Page 12: ...trated Make 3 15 16 Body length 20 Fitting the soundboard to the sides a pencil mark on the centerline on the underside of the soundboard Measure 20 from this mark to the tailblock end and make a mark This is the body length During glu ing these marks must align with the sides and blocks The soundboard will overhang the sides a little which will be trimmed away later KIT TIP Trimming soundboard ov...

Page 13: ...t the neck block using four clamps on each side up to the waist clamp By gluing the neckblockandshoulderareafirst theangleofthe neckset won t be affected if you need to pull or push the tailblock to the 20 mark Installing the soundboard 3 Align the sides at the tailblock end with the body length mark and clamp as you did the neck block 4 Start installing spool clamps at the tailblock use seven on ...

Page 14: ...ry before unclamping Back bracing and fitting Installing the back bracing Fitting the back to the sides Trace the curved brace onto a 2x4 and cut on a bandsaw for a curved back brace caul If you haven t yet leveled the back kerfed linings do so now Use the 5 wedged sanding board When correctly installed the guitar s back will have an arch with curvature both longitudinally and laterally and will h...

Page 15: ...dry clamp each strip to make sure it lies flush with the guitar side You may want to make a small caul to help hold the strip and spread the clamping pressure with an accompanying outside caul for backup Experiment with C clamps springclamps orcamclampsuntilyoufindacom bination that works for you Apply a thin bead of Titebond clamp the strips in place pictured and allow at least an hour before unc...

Page 16: ...ur workbench for most of the routing and remove it to rout the waist of the body Wood tear out is always possible when routing but espe cially with long grain quartersawn tonewoods Therefore start with four climb cuts so called because the router is climbing or being pulled along as the bit grabs the wood Withasaw chiselandfile removethesectionofsoundboard that covers the top of the neck joint cav...

Page 17: ...sults You llneedtoswingoutasyoureachthefirstshoul der swinginasyounearthewaist andswingoutas you approach the last brace This isn t easy if you re alsotryingtomaketheclimb cutstoavoidtear out Ifyouignoretheclimb cutsandrouttheentireback in a counterclockwise direction you ll have more control In that case lower the bit in several passes andusetapeontheball bearingtomakeshallower cuts in stages to ...

Page 18: ... Weld On glue to a section of the routed soundboard channels from about six inches to one quarter of the distance around the guitar from the tailblock seam Set the herringbone trim in place the pattern should point toward the neck block Ap ply a little more glue on its edge and set the plastic binding strip against it in the outer channel You can glue both strips simultaneously Secure them tightly...

Page 19: ... as a reference and wrap tape around the reamer as a depth stop for the remaining holes Align the nut end of the fretboard with the break angle where the peghead begins Pencil a mark on the peghead face 3 16 from the nut line Align the peghead overlay with this mark This will leave some extra overlay wood to be trimmed away when the nut is fitted later Using Titebond glue and clamp the rosewood ov...

Page 20: ...face of the dovetail or bolt on tenon Mark the length of the adjustment nut on a 17 64 drill bit with masking tape to act as a depth stop Run the bit in reverse to start the hole and then drill open the truss rod slot to accept the nut Now slide the Hot Rod Truss Rod into the neck channel from the heel end with the adjustment nut down Set the neck into the neck block Using a 1 8 hex wrench check f...

Page 21: ...ape pictured Making a fretboard Trimming the fretboard Mark the location of the pearl fret markers on the fretboard using the centerline that you made earlier The largest marker will be inlaid at the 5th fret middle sized markers will be inlaid at the 7th and 9th frets smallest mark ers at the 12th 15th and 17th frets two markers are inlaid at the 7th and 12th frets For single fret marker position...

Page 22: ...t for possibly easier fret instal lation but also may produce an occasional loose fret end Set the first fret in place and hold it so that it can t tip to prevent wood chipping pictured Seat the two fret ends with one sharp hammer blow each then hammer back and forth across the fret Since the fretwire is more curved than the fretboard the fret straightens as it s hammered in This causes the barbs ...

Page 23: ...e surface and align the nut end with the nut line on theneck Tietherubberbandatthenutend andstartwrap ping pictured The fretboard will align itself as you wrap and can be easily moved if one edge overhangs Stretch the rubber band tightly as you wrap toward the neck heel go around the neck joint and the heel and then wrap back to the nut Even with a light glue application you ll probably get a lot ...

Page 24: ...erdoing it with any one tool KIT TIP Neck sizes Although the neck has been machined to reason ably close tolerances plenty of extra wood has been left to accommodate different neck sizes and shapes You can make tracings from the blueprint andcutoutneckcross sectiontemplatesforcheck ing the shape of the back of the neck if you like We penciled the entire backside of the neck and used our files at a...

Page 25: ...uter edges of the heel make contact with the body and these edges set the neck angle illustrated on next page The contact area of the heel is an area about 1 8 to 3 16 wide around the outer edges of the bass side treble side Fitting the neck to the body and bottom of the cheeks Mark this area on the heel with a pencil Using a sharp chisel remove wood from the remain ing inner area up to the tenon ...

Page 26: ...the treble or bass cheek Wood removed here controls the side to side alignment of the neck to the centerline If the neck is misaligned side to side one of the outside E strings will be too close to the edge of the fretboard A tiny amount of wood is all it takes to make an adjustment here Remove this bit of wood uniformly across the contact area on one cheek to tip the neck in the proper direction ...

Page 27: ...ood make two or three passes before changing to the other cheek The fit will change rapidly so check your progress frequently A small ledge of unsanded wood will remain on the bottom of the heel between the sanded cheeks Either pull sand it with the strip or use a sharp chisel to remove it emoving wood from the top edge tips the neck upward Removing wood at the bottom edge tips the neck back Wood ...

Page 28: ...t be filed and sanded onto the bottom of the nut Leave the top surface of the nut untouched for now From a scrap of wood at least 1 2 thick 2 3 wide and long enoughtoclamptothepegheadface makea sawfence by bevelingthethinedgeat15 pictured Holdthenutblank beveled side down firmly against the end of the fretboard butt the saw fence against it on the peghead and clamp it in place Remove the nut and u...

Page 29: ... thinner or course but it s nice to have thinner around for cleanup Feel free to apply the finish of your choice however according to the manufacturer s di rections If you decide to use spray equipment always thin nitrocellulose lacquers with nitrocellulose thinner only KIT TIP Aerosol Lacquers Aerosol lacquers have a tendency to spit if the spray tip gets clogged Wipe the tip clean often Also you...

Page 30: ...cquer finish won t fill Filling the fret ends The neck needs extra sanding and grain raising in the end grain areas of the heel and the ears and the end of the peghead Sand up to 320 grit dampening to raise the grain Dothisseveraltimes sotheendgrainporeswillabsorbstain more uniformly for a better appearance Sanding the neck To fasten a spraying handle to a bolt on neck drill two holes inascrapwood...

Page 31: ...g the grain filling process you can use a rag lightly dampened with water to soften anyfillerthat shardeningtooquickly Whenthewoodpores have been filled and wiped level a bit of blotchy hazy resi due will probably remain on the surface Let the wood dry overnight Light sanding with 320 grit Fre Cut may be required to remove any remaining buildup of filler on the wood surface Try to avoid sanding th...

Page 32: ...grit again This time most of the shiny spots will disappear leaving KIT TIP Wet sanding Soak the micro finishing paper in water overnight beforeuse Itwillscratchless andlastlonger Always keep it wet from then on Using soft cloths or an electric hand drill with foam polishing pads rub out the fine wet sanding scratches to a final gloss with medium and fine polishing compounds Use a separate pad for...

Page 33: ... five to ten minutes as it squeezes out using a clean damp cloth Remove the clamps after the glue has dried For the dovetail neck apply Titebond glue to the underside of the fretboard extension the two sides of the dovetail and if you wish add a small amount on the interior walls of the neck block dovetail mortise Be sure glue contacts both sides of the shim too Slide the dovetail neck and the shi...

Page 34: ...between the straightedge positions and mark the bridge s side locations on the soundboard with masking tape To square up the final location be sure both sides of the bridge s front edge are equidistant from the last fret Prepare three small wooden clamping cauls to fit over the center and sides of the bridge pictured Use a hand plane Apply Titebond to the bridge and reclamp the bridge in place on ...

Page 35: ...he slot depth and compare it to the saddle depth indicated by the penciled line they should match Keep fitting until they do You ll feel the saddle click into the slot when it reaches the bottom Fitting the bridge saddle Withthetunersinplaceonthepeghead markthemounting holes with a scribe or an awl through the small holes on the baseplate Remove the tuners and drill the holes with the correct size...

Page 36: ...e nut and bridge saddle have been shaped to a 16 radius to match the fretboard but they re still too tall at this point Installing the two outside E strings will help establish the string spacing at the nut the string clearance over the first fret and the saddle height above the top of Nut slotting saddle adjustment and string action the bridge The latter two measurements determine the action heig...

Page 37: ... the strings by measuring equally from their centers or you can graduate the spacings to accommodate the larger diameters of the wound strings The thicker wound bass strings if spaced equally on their centers wouldbeclosertogetherthanthesmallerunwound treble strings File shallow slots and tune to standard pitch Using a small razor saw and several nut slotting files lower the strings oneatatime unt...

Page 38: ... a little for exact placement Working from the center of the pickguard carefully squeegee out the water to remove bubbles and air pockets from beneath the pickguard and let it dry overnight Installing the pickguard Reinstallthenut withoutglue andplaytheguitar Checkfor false notes or string buzzes caused by uneven frets Buzzing is corrected by leveling the frets Remove the strings and the nut mask ...

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Page 40: ...21 N Shafer St Athens Ohio 45701 USA USA Canada call toll free 800 848 2273 9am 6pm weekdays Eastern time 24 hour fax 740 593 7922 www stewmac com i 5295 04 08 ...

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Stewart MacDonald 5295, Assembly Instructions Manual

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