Stewart MacDonald 5297, Assembly Instruction Manual, Page: 7 / 42

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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 1-1/4" tall block of scrap wood onto the card-
board, centered about 4" from the smaller end of the guitar
mold . Then glue a second 1-3/4" tall 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
3/4"
Blocks:
1-1/4" tall
1-3/4" tall
Corrugated
cardboard
9-1/4"
6"
2"
2"
13-1/4"
Waist Clamp
Made from 3/4"-thick plywood
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