Project Telecaster

There's always something that doesn't fit. So why not build yourself a guitar. Especially when you already bought a template.

If you have a template and a milling cutter ... it seems easy.

First, you draw the contour. It is based on the center line, which should follow the grain.

This is sawn out with a few millimeters supernatant. With alder, also a cheap band saw and of course almost any jigsaw is enough. The complete milling would be more time-consuming - by normal means.

Then stick or screw the template. Now you mill in steps down with a copy milling cutter with overhead storage ring. In the first step, a problem becomes clear. If the milling cutter has a long edge, you have to mill much material at a time. So possibly mill around without pressure.

When you reach the maximum depth of the cutter, it goes on without template.

Then turn around and finish with a copying cutter with bottom-copying ring. Also works good on the spindle moulder.

Milling out the pockets seems to be a problem. I used a 10mm thick stencil. The 1" profile miller can thus not be used at the beginning .... if you stand in front, you know immediately what is meant.

I have improvised and used a 17mm copy ring (Bosch Standard) on the cutter and a 80mm long cutter from metal processing, at least for the electronic stuff and the bridge pickup. For the other pockets of the copying ring was too wide.

So I milled the remaining pockets by hand with the much too small CNC. There are cheap 1/4 "cutters with 3/8" edges for the router, but it's a hassle without appropriate tools and these are not low-priced at the hardware store.

The hole for the input jack can be drilled with a 22mm Forstner drill. For other holes, the template is fine, there are no problems. The holes for the tailpiece come up impressive, but do not forget to drill the outer diameter 2mm deep first, otherwise the paint breaks.

Here already with the P90 cover which is not available, you have to mill it yourself.

Now the next challenge: painting. I always make a fuss, because I can not wait and I do not have the possibilities for a perfect high-gloss finish.

I wanted an "old-fashioned" paint, and chose resin. 2x filler and 2x paint takes a long time, because the paint dries slowly, but it is nice and smooth. The thin layer is sensitive as nitro lacquer, but has not the disadvantages.

It is kind of a certain "relic look", probably during polishing ... if you boost a little.

The neck is made by Allparts, which was processed fairly good. To bring the color into the desired direction, I yellow stained it and then painted the headstock, the fretboard is oiled.

Compared to an untreated neck.

Grinded, over-polished and the corners stained dark, where wood looks through the paint. Provided with the hardware, set, ready. Especially appreciated was the signature on the pickguard : -) luckily I had a second one, neutral milled.

Pickups are a Rockinger P90 at the neck and a SD Lil '59 at the bridge. They go well together, individually almost identical loud. With splitted bridge position, it sounds like a Tele, the middle position is a bit indifferent.