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Before any fretting could be done, we needed to make sure the neck was straight and flat. I used a large sanding block with the proper radius (20” in this case) after the truss rod was adjusted to the appropriate tension and level-sanded the fingerboard. With chalk marks on the ebony to help guide me it was just a matter of sanding it away until the chalk disappeared. With that complete I spent the next few minutes cutting the long fret wire into actual frets that hung over about 3/32” on either side of the fingerboard. It was also my first time using a fret tang clipper, which basically removes the tangs from the ends of the frets so they can fit into the slots. I made several errors learning to use the tool and had to recut a few frets but once I got the hang of it, it was really easy to complete.
Next up was the first and only time I’d get to take a hammer to the guitar. Fretting was done with a brass hammer and a wood block to protect the frets. It almost seemed a bit barbaric to begin, with but the process went very smoothly. Put a drop of glue in the fret slot, set the fret in, and tap it in with the hammer. You could apply a pretty good amount of force to make sure it went in all the way but it definitely required a little finesse so as not to beat up the wire too badly. Once the frets were over the body we needed to set up a support mechanism between the body and neck to ensure I didn’t crack it when hitting it with the hammer. George assisted in this and we got through the first part of the fret job fairly fast.
After the frets were installed I used a nipper to cut the excess fret wire off at a slight angle to the fingerboard. Leaving very rough edges (obviously), the next step was to use a sanding block that created the perfect angle to the frets at the edge of the fingerboard. This step required using my hand to feel if anything was jutting out, and after a time I had both sides of the frets smooth and ready for the level, crown, and polish. Leveling couldn’t be much easier as it used a large sanding block to bring them into the correct radius. We used a felt tip pen to mark the top of the frets much like the chalk to see where the sandpaper had hit until they were all erased. I then used a file to round the edges off the frets to a 3-point smooth end. Again, though I’d never done this before, it seemed fairly easy to accomplish after a little practice. The final stage was polishing, and we all know that’s just another name for sanding, which is exactly what it was: a long process of using graduating degrees of microgrit sandpaper to remove all scratches and leave the frets shiny and complete.
Day 14: Final Setup
Slotting the nut
But before I get to that let me finish up with the fret slotting. For the next hour I filed a little away at a time on the nut and continued to measure using feeler gauges to make sure the slots were cut to the correct depth. This became a combination of numbers and feel, and in the end the nut was cut to a comfortable-but-not-too-low depth. Since the saddle was a bit high I ground it down slightly to make the action comfortable and that concluded the build!
For the next hour or so I just played the guitar and marveled in the accomplishment of actually building an instrument. My biggest concern all along is I’d make something comparable to a $500 classical guitar, but that was not the case at all. In fact I’d happily put this up against guitars in the $3-4K range and feel very comfortable. After all, people who know their instruments conceived the design. I now believe that the impossible is possible, with a little time and care put into it. There are flaws. I can see them in the finish, in places where my work wasn’t perfect. But overall, as a hand-built instrument and as my first ever build, I’m blown away.
As the weeks have gone on, my guitar is opening up so that each time I play it you can hear it starting to breath a bit more. The stiffness is slowly going away, but that will take some time and a lot of playing, which I’m sure will be no problem at all.
For those of you who have followed this and wonder if it’s something you could accomplish I can say with total confidence that the answer is a resounding yes. With the help of dedicated and fine luthiers/teachers like George and Diana, it’s very possible to create your own work of playable art. Will I be able to work for Collings or Taylor as a builder now? No, but that wasn’t the point of taking this class. The point was to live a lifetime dream and that’s exactly what it was. Fulfilling, satisfying and incredibly fun and rewarding. Thank you Phoenix Guitar Company!