My first homemade guitar had three main objectives: learn how to make a fretboard, learn how to install a truss rod, finish as soon as possible. So this post is about that first goal.
I found a scrap of cocobolo at my local wood store just thick enough to be the fretboard and long enough to also be the front face of the guitar head. I did a bunch of sanding to get it to an even thickness (forgot to take pictures of all of this). I decided I wanted to have a radiused fretboard instead of flat, so I started by making a radius sanding block.
I actually tried 3D printing, but it was really really slow. So I gave up long before my block was a useful length. Instead I turned to a much faster process, laser cutting. The two holes are for dowels used to align all the pieces in gluing.
![IMG_0980](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_0980.jpg?resize=1024%2C768)
After gluing the stack together, the radius surface was still quite uneven due to the slight draft on each layer. I did some sanding to take off the really high peaks, but decided it was faster and easier to smooth things out by just gluing a thin sheet of metal over all of it.
![IMG_0990](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_0990.jpg?resize=1024%2C768)
![IMG_0991](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_0991.jpg?resize=1024%2C768)
![IMG_1009](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1009.jpg?resize=1024%2C837)
Next I drilled some shallow holes to accept maple fret markers that I made using my homemade plug cutter.
The photo below also shows the ‘jig’ that helped me cut the slots for the frets. I used the water jet to cut the aluminum plate that the fretboard is double-sided-taped to. The plate has holes that are spaced the way the frets are spaced. So with a pin on my miter box, I can easily get accurate spacing for all the slots. I forgot to take pictures of all that, too…
![IMG_1276](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1276.jpg?resize=768%2C1024)
![IMG_1277](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1277.jpg?resize=768%2C1024)
After the glue dried, I flush cut all the markers and began the long process of sanding. Started with 80 grit and worked down to about 220. I used double sided tape to adhere the sand paper to the radius sanding block.
![IMG_1278](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1278.jpg?resize=768%2C1024)
![IMG_1280](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1280.jpg?resize=1024%2C768)
![IMG_1282](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1282.jpg?resize=768%2C1024)
With the slots cut (and the fact that my blank was quite thin to begin with) the fretboard is quite delicate. I used a heat gun on the aluminum plate side to weaken the double sided tape, and then used a card to shim them apart.
![IMG_1470](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1470.jpg?resize=1024%2C904)
Then I marked out the taper shape and roughed it into shape on a belt sander.
![IMG_1471](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1471.jpg?resize=1024%2C553)
![IMG_1472](https://amymakesstuffdotcom.files.wordpress.com/2018/01/img_1472.jpg?resize=1024%2C547)
After this I glued it to the neck and then hammered in the fret wire – hopefully all detailed in a post coming soon!
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