Stewart MacDonald 5297, Assembly Instruction Manual, Page: 13 / 42

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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
20-3/8" 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
the end positions of the X-braces and the large shoulder
brace . Remove the soundboard and trace the brace posi-
tions onto the kerfed linings with a straightedge, using the
marks as reference points . For the X-braces, be sure to hold
a long straightedge between the reference points at the
proper angle . The positions of the tone bars should also be
marked if you choose to notch them . The tone bars don’t
notch in as deep as the other braces, and only a slight filing
will be needed .
With a knife and/or file, remove wood from the linings and
the sides in the penciled areas to accomodate the ends of
the braces . These notches should taper toward the interior
of the guitar to match the taper of the braces (pictured) .
When the notches are cut correctly, the top will fit into place
and be ready for gluing .
Opening the dovetail joint
Before gluing on the top, remove the side wood covering
the neck joint opening in the neck block . With a sharp stiff
knife or a saw, score through the sides until the waste wood
can be snapped off up to the scored line . Follow with a sharp
chisel and a file to smooth the sides flush to the inner walls
of the dovetail .
Stewart-MacDonald’s tool recommendation
Guitar Brace Chisel
Item #1615
This specially curved blade makes it easier to create the smooth curves needed for
scalloped braces and tone bars with feathered ends . Great for removing dried glue
from the sides of the braces, too . High quality steel blade and balanced wooden
handle .
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