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Страница 1: ...Campfire Mandolin Kit 5160 Assembly Instructions Stewart MacDonald www stewmac com Campfire Mandolin Kit 5160 Assembly Instructions Stewart MacDonald www stewmac com ...

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Страница 3: ... fretboard to length 8 Plane the fretboard taper 9 Inlay the pearl position markers 9 Inlay the white side dots 9 Shape the braces 10 Fit the top to the side assembly 10 Glue the top on 11 Level the fretboard 11 Install the frets 12 Install the fretboard 13 Remove the cardboard mold 13 Fit and glue the back on 13 Shape the neck 13 Level and polish the frets 14 Install the tuners 14 Trim the top ba...

Страница 4: ...s Cam C spring Spool clamps 0683 see Glue the top on for options Kerfing clamps or clothespins Drill and bits 9 32 1 16 1 4 Rat tail file or small dowel wrapped with sandpaper Mill file Half round bastard file or sanding block Nut files or small 015 razor saw 3597 042 width 0833 028 width 0830 016 width 0827 X acto blade sharp knife Chisel Flux brush for spreading glue Straightedge 3799 Ruler in t...

Страница 5: ...A strip of waxed paper between the caul and the sides is also a good idea Allow the Tightbond to dry for 3 hours When the neck block is dry glue the tail block in the same way If you have enough clamps glue both at the same time Withthesidesgluedon themountingholeintheneckblock is covered Drill this hole through the sides with a 9 32 bit using the neck block hole to guide the drill There probably ...

Страница 6: ...t placingthemveryclose together Some clothespins have weak springs and can be strengthened by wrapping each with a rubber band When you re ready spread glue on one section of kerfed lining and clamp it in place A plumber s flux brush hard ware store item spreads glue to the right thickness under clamping pressure you should get just a slight squeeze out of glue making cleanup easy Gluethekerfedlin...

Страница 7: ... a weight for clamping pressure cut a scrap wood caul in the shape of the patch and put a sheet of waxed paper between the caul and the patch Add weight to the caul and allow it to dry for at least an hour Transfer the bracing patterns to the top and back Glue the soundhole patch in place The sanding stick of 1 4 plywood is supplied for shaping the curved braces and will also be used later for san...

Страница 8: ...lts dothisintwopasses first rough cut the hole without coming quite up to the edge then carefully pare away the wood following the shape of the soundhole With a file or 150 grit sandpaper lightly bevel and smooth the underside of the soundhole and soundhole patch Rough out the top and back Attachastripof80 gritsandpapertocoverthesandingstick using glue double stick tape or self adhesive sandpaper ...

Страница 9: ...top and back for gluing Use the sanding stick to do this attach a 7 strip of fresh 80 grit sandpaper to the 20 stick Fasten this piece of sandpaper about 7 in from the end of the stick At the opposite end of the stick fasten the 4 piece of ply wood with glue or double stick tape This raised section will rest on one side of the mandolin rim while the sandpaper works on the opposite side The thickne...

Страница 10: ...ngtapeoneachsideofthechan nel for the reinforcement bar to keep any glue squeeze out off of the surface of the neck Spread epoxy glue into the channel and press the reinforcement bar in place Make sure thatitisflushwiththenecksurfaceandnotextendingabove thechannel whichwouldinterferewithgluingthefretboard later Wipe off the excess epoxy and remove the tape Let it dry according to the glue manufact...

Страница 11: ... and 15 and two dotswillmarkthe12thfret Centerthedotsbetweenthefret slots the dot for fret 5 will be centered between fret slots 4 and 5 etc At the 12th fret drill two holes 1 4 apart The side dots are created with the thin white rod Place a drop of superglue in one of the holes push the white rod in and nip it off so a small amount is left protruding from the hole Do this with the remaining holes...

Страница 12: ...hing the centerlines and lightly clamp the top to the neck block and tail block to hold it in place In pencil mark lightly on the sides where the ends of the braces meet the sides Also pencil the shape of the sides onto the ends of the braces for trimming Removethetopandlayastraightedgeacrossthesideassem bly and line it up with the marks Pencil the brace location across the kerfed lining Use a sha...

Страница 13: ...s Whenalltheclampsareon re clamptheneckandtailblock Removetheirclampsandreapplythem beingsurethattheir wooden cauls are spreading the pressure across the entire block If you have extra clamps use two especially on the larger neck block Gluing method 2 Weights Using the pressure of weights is an alternative to clamping Place the top face down on a ring of wood scraps left over from shaping the back...

Страница 14: ...y 1 64 away from the side of the fretboard to avoid marring the wood Fret nippers are ideal for this purpose providing a clean flush cut Wire cutters will do the job if you don t have fret nippers When 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 frets pressed into the slots will slightly curve the fretboard into ...

Страница 15: ...cate the notches and cut them trim the brace ends and glue the brace on the back using clamps or weights Fit and glue the back on Use a razor knife to cut and remove the cardboard inner mold Remove the cardboard mold When the fretboard has dried use a half round bastard file or a sanding block to smooth the shape of the neck and make the fretboard edges flush Block sand the neck with 150 grit then...

Страница 16: ...mask ing tape on the drill bit to mark the screw hole depth Install the tuners It s time to shape the edges of the top and back to match the sides If your rough shaping of the top and back left a lot of wood exposed you ll want to saw it away now so that you have a small overhang around the sides approximately 1 8 Removetheoverhangwithahandplane oraknifeand file Trim with the grain to avoid splitt...

Страница 17: ...tendingoverthe tape at the tail block Measure from the straightedge to the centerline and then do the same on the opposite side If the measurementsarenotequal theneckisnotcentered Gently push or tap the neck to correct any misalignment Once the neck is aligned tighten the neck bolt more snugly at this point finger pressure should still be all that s needed If the neck won t align with the center u...

Страница 18: ... bridge bottom needs to fit the curved top To get a good fit sand the bottom of the bridge by laying a strip of 150 grit sandpaper on the top and move the bridge back and forth Fit the bridge Scratch starter notches into the pencil marks with a sharp scribe and then use your smallest razor saw or nut file to begin the slots The three nut file sizes we use on a man dolin nut are 042 G string 028 D ...

Страница 19: ...e deeper than half the diameter of the strings remove a little material from the top of the nut As you file or saw the nut slots if they get too deep to cut cleanly stop and remove some excess material from the top of the nut Adjust the string height When the nut slots are finished de tune the strings and remove any excess nut material Use a smooth file and 220 grit sandpaper to smooth the nut and...

Страница 20: ...nish 1 Mix well prior to use Stir gently do not shake to minimize bubbles 2 Sand grain filled wood with a minimum of 320 grit sand paper Remove dust with a soft cloth Do not use wax oil tack cloths Wash the surface with Naphtha or denatured alcohol to remove any oils 3 Apply thinned varnish as a sealer Thin with up to 50 water Apply 2 to 3 coats of sealer 2 hours apart Scuff sand the first coat wi...

Страница 21: ...bridge before tightening it The bridge is held in place by the string tension and no glue is used The correct location for the bridge is 13 61 64 from the nut edge closest to the bridge to bridge edge closest to the nut The portion of the fretboard which overlaps the top is called the extension and on some mandolins this extension is glued to the top You might choose to do this but it is not neces...

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Страница 24: ...21 N Shafer St Athens Ohio 45701 USA USA Canada call toll free 800 848 2273 9am 7pm weekdays Eastern time 24 hour fax 740 593 7922 www stewmac com Stewart MacDonald i 5160 Updated 11 06 ...

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