Stewart MacDonald 5348 Assembly Instructions Manual Download Page 1 | Manualshive

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Tenor Ukulele Kit

#5348 Assembly Instructions

www.stewmac.com

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Summary of Contents for 5348

Page 1: ...Tenor Ukulele Kit 5348 Assembly Instructions www stewmac com ...

Page 2: ...p onto the sides 7 Trim the top 8 Glue the back onto the sides 8 Fret and neck installation Install the side dots in the fretboard 9 Seating frets 9 Attach the fingerboard to the neck 10 Level and polish the frets 10 Dress the fret ends 11 Preparations for attaching the neck to the body 11 Attach the neck to the body 12 Finishing your ukulele Locate and mask the bridge 13 Final sanding and masking...

Page 3: ...nstructions use a Soprano uku lele as a model though the technique is the same for either Soprano or Tenor uke 3 If you re new to building here s a tip that every instru ment builder knows or finds out the hard way Test the fit of any parts before you glue them Dry clamp to see that everything fits then use glue 4 Be safe when using tools glues and chemicals Wear eye protection and gloves when nee...

Page 4: ... cam C bar clothespins and spring clamps Laminate trimmer with flush trim bit or chisels hand plane and sandpaper Hand plane or sharp utility knife and files Mill file wood rasp and or Microplane Half round bastard file or sanding block X Acto hobby knife sharp utility knife 032 nut slotting file 0831 or fine tooth hacksaw blade Fret hammer 4895 or light weight hammer with smooth head Fret cutters...

Page 5: ...nd Draw a centerline down the length of the body jig base Measure accurately because you ll use this line to guide you in building Assemble the two side walls on the neck and tail end of the base so the interior walls will be 12 apart pictured Use a square to be sure the sides are perpendicular to the centerline Glueandfasteneachwallwithtwodrywallscrews from the underside of the base and let dry f...

Page 6: ... on the respective sides of the neck block for reference in future steps Use a small piece of wax paper between the neck joint and your bench wrapping it up the outside so that it goes between the sides and the caul The wax paper will protect your bench and caul from the glue Using clamps of your choice bar clamps work best dry clamp the neck block in place Attach the neck block It s now critical ...

Page 7: ...ly deeperthantheneckend Asaresult thebackliningswillrun at an angle from the tailblock down to the neck block Working with the back of the side assembly trim the lin ings so the ends fit against the neck and tailblocks and dry clamp them with clothespins or 1 spring clamps Adjust the linings to taper gradually from the tail to neck block at the same angle on both sides When you re satisfied with t...

Page 8: ...o the braces clamp them in place and clean up any glue squeeze out Allow 3 hours to dry Bracing the top and back Hold the purfling strips in a stack alternating white black white black white With a sharp X Acto knife trim one end flush and square Carefully set the strips into the channel with the squared end at the centerline at the top of the soundhole When you complete the circle carefully trim ...

Page 9: ...e sides Dry run Clamp the top to the sides using a cam clamp at each end of the assembly Carefully line up the centerline on the top with the centerline of the sides Use the rubber bands to apply even clamping pressure to the top Caution Before gluing be sure you can get your fingers through the soundhole to release the turnbuckle so you can get the assembled sides and top out of the body mold Whe...

Page 10: ...ise Routup totheareasindicatedbythearrows Whenallfourclimb cuts have been made you can move the router in the opposite direction counterclockwise cutting into the wood rather Trim the top A B Puttheassemblybackintothemold topdownandoncenter Now using your hand plane plane the edges of the sides down to the linings Make sure you plane downhill so that you don t get tearout When you get close to the...

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Page 12: ...Tenor ukulele body shape template and bracing pattern Waist 4 1 2 from neck end Top brace and Back brace 5 5 16 from neck end Top brace 1 7 8 from neck end Taper the brace ends with a sharp chisel ...

Page 13: ...Back brace 8 15 16 from neck end Body length 12 Bridge plate 8 9 16 from neck end ...

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Page 15: ...ted nip the overhanging ends close to the sides of the fretboard approximately 1 64 Leaving a little overhand helps you avoid marring the wood You can use wire cutters but fret cutters are ideal for this job and provide a clean flush cut After all the frets are installed place a flat hardwood block on top of the frets and hammer on the block to further seat the frets The fretboard will now have a ...

Page 16: ...s important to have the 14th fret right at the edge of the heel of the neck Reclamp clean up squeeze out at the nut area and let dry for at least 3 hours Final sand the neck Remove the clamps from the previous step Secure the peghead to the workbench or in a vise Using a combination of micro file or finish rasp and sand paper file the neck and fretboard sides flush Clean up the dried glue but avoi...

Page 17: ...p edge and the other 1 1 4 from the top edge Final sand the body Clamp the peghead to the workbench Using a micro file or finish rasp file the neck flush to the fretboard sides Finish with 220 grit sandpaper Sand the body down to 220 grit sandpaper Clean up the neck heel Check for glue squeeze out between the fretboard and the neck heel If necessary remove it with a chisel Now hold the neck assemb...

Page 18: ...wo spacers on the body outline put two 1 4 dowel center ingpinsintotheholesyoudrilled andcarefullyputthebody ontotheMDFfixtureandslideitupagainsttheclampedneck in order to mark the centers of the two holes Alignmentiscritical Remove the neck and drill 1 2 deep x 1 4 holes at the markings Put the dowel pins into the body and check the fit with the neck Adjust as necessary Now dry clamp everything i...

Page 19: ...and mask that area off with tape to keep the wood bare during finishing The bridge will be glued on later after the finish has been applied to the instrument Placethebridgeonthetopofthebodyinapproximatelythe correct place 17 3 32 from the nut end of the fretboard to the center of the saddle on the bridge Now place a piece of 1 1 2 wide masking tape on the top of the body under the bridge Finishing...

Page 20: ...om 8 10 inches away Apply thin coats in steady uniform strokes to achieve the desired finish Tip Pro shops spray heated lacquer because cold lacquer spatters requiring extra sanding You should warm up your aerosol lacquer too simply soak them in a sink of warm tap water 3 Allow at least four hours between coats and wait 24 hours before level sanding Let the finish cure for 10 14 days before final ...

Page 21: ...t angled relative to the fretboard When you have it located put small pieces of masking tape on the top outlining the bridge Now dry clamp it with the saddle removed to make sure that the clamps you have selected will work well RemovethebridgeandspreadasmalllayerofTitebondglue on its underside Put the bridge in place and clamp it Pull up the masking tape and clean up any glue squeeze out Allow to ...

Page 22: ...mple the distance from the G string and the first fret should be 015 If you don t have nut slotting saws you can adjust this slot with a fine tooth hacksaw blade Check the height of the string at the 12th fret this should be 090 To adjustthisheight sandmaterialoffthebottomofthesaddle Onlythenutadjustmentwillbeneededfortheotherstrings That s it You ve built a ukulele and you re ready to play Set th...

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Page 24: ...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 5348 8 15 ...

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