Stewart MacDonald 5295, Assembly Instructions Manual

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Using the two heavy cardboard body forms (supplied with
the kit) create a guitarmaking form which supports the body
during the early stages of assembly .
First, place two scraps of 3/4" plywood onto the work surface
inside the guitar . This will lift the cardboard form up to make
room for the kerfed linings which will be installed later . Lay
the first cardboard piece onto the 3/4" plywood inside the
guitar body .
Next, glue a 2" thick block of scrap wood onto the cardboard,
centered about 4" from the smaller end of the guitar mold .
Then glue a second 2-1/2" piece of scrap wood, centered
about 4" from the bottom (larger end) of the guitar mold .
Glue the second piece of cardboard onto them . Now the
two cardboard forms are fastened together with blocks of
wood between them, creating a three-dimensional form for
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, install the waist clamp from the back side of
the guitar . (Later, after the top is installed, you'll switch the
waist clamp to the top side) When sliding the waist clamp
on, hold the guitar sides tight against the cardboard form
to keep from cracking the sides . If the fit is too tight, remove
small amounts from each side of the U-shape until the waist
clamp slides snugly onto the waist (but not so snug that it's
hard to remove) .
Making a body mold
Rounded
edge
Waist
clamp
2" block
2-1/2"
block
Corrugated
cardboard
Workboard
3/4"
scrap
10-13/16"
6"
2"
2"
14-13/16"
Waist Clamp
Made from 3/4"-thick plywood
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