Stewart MacDonald 5295, Assembly Instructions Manual

Page: 12 / 40

stewmac.com
To fit the top, the ends of the X-braces and the tall shoulder
brace must be notched into the kerfed linings . The remain-
ing smaller braces will be tapered to nothing where they
meet the kerfing .
KIT TIP: Tapering smaller tone bars
The blueprint shows the ends of the T-2 tone bars
notched into the kerfing, but we now suggest that
you taper them before they reach the kerfing . The
choice is yours . Tapering these braces to nothing
will let the top flex a little more .
For this fitting, leave the side assembly clamped to the
workbench if you’re able to work around the assembly com-
fortably . You can unclamp the side assembly and the waist
clamp from the workbench if it makes fitting the top easier,
but be sure to handle the assembly gently . Don’t bend or
twist the sides as you fit the top .
Chisel the ends of the X-braces and tall shoulder brace down
to a thickness of .100"
(pictured)
. Follow the pre-machined
taper of the braces as you chisel .
To find the guitar’s accurate length between neck and
tailblocks, first measure 3-15/16" from the top edge of the
soundhole, towards the neck block
(illustrated)
. 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 overhang
An option to leaving the top overhang is to remove
it in the neck block and tailblock areas only . This
gives you an opportunity to re-check the square-
ness of the sides to the top in these areas during
gluing . If you trim the overhang flush, then during
gluing, you can butt the top and sides at each end
until they are flush to ensure squareness . This way,
the top fits the sides, neck block and tailblock accu-
rately, and you can ensure that the body measures
20" from end-to-end .
Using a 3/4" x 2" x 3" scrap wood caul and two cam clamps,
gently dry-clamp the top to the neck block . Next (if nec-
essary), pull the sides and tailblock into the body length
pencil mark (look at the mark on the underside) and gently
dry-clamp that end . Don’t use excessive pressure, since the
braces to be notched will be resting on the kerfed lining at
this point . On the guitar’s sides, use a white pencil to mark
10