
Here are the good and bad habits to look for when you’re watching a builder at work.
It’s fun to binge-watch YouTube videos, and for guitarists there are a plethora of them to behold. There are mashups of metal and funk, as well as never-before-seen footage of classic acts in every genre. Then, there are the how-to videos that have helped me and countless others learn new fretboard moves. My favorites are the ones that decode songs, unlocking finger positions and chord voicings that have eluded me for years. But next to that, I enjoy watching guitar-making videos. As a builder whose 50-year career has allowed me to tour and work in dozens of guitar factories and shops, you might wonder why on earth I would subject myself to this. The answer is that you can always learn something new if you know what to watch for. New and correct information is certainly what most of us are hoping for when we spool up a video.
The first thing I look for is if a shop is organized and relatively clean. I say relatively, because woodworking is, by nature, somewhat messy. All that cutting and sanding creates shavings and dust that’s hard to control completely. Most decent shops have some sort of dust collection, so when you spy ankle-deep wood shavings, you might wonder where the priorities are. Wood dust is flammable at best and explosive at worst, so if you buy a guitar from a shop that’s a ticking time-bomb, you may not be able to count on any long-term customer service. I’ve written before about the benefits of being well-ordered, and I think that it speaks volumes about the builder’s attitude. Clutter slows things down as little interruptions in the workflow add up to mistakes or even bankruptcy. I’m not saying that great work can’t be done in a messy shop, but I’m not a gambling man either.
“Wood dust is flammable at best and explosive at worst, so if you buy a guitar from a shop that’s a ticking time-bomb, you may not be able to count on any long-term customer service.”
For a guy who hates hammers, I’ve got a lot of them. Sometimes it’s the only tool that will get the job done. One task that a hammer isn’t good at is fretting. Sure, that’s the way it used to be done back in the good old days—you know, when all those unplayable budget guitars were being sold at department stores. I cringe when I see builders smacking a neck with a hammer, and you should too. In a repair shop, there’s room for the hammer as an adjustment tool, but it takes hundreds of hours to get really good at it.
The problem is that hammers aren’t very consistent, and seating frets properly demands uniformity. Hit the fret a little too hard and it’s buried, not hard enough and you get a high fret. That’s why the best shops use a mechanical press of some sort.
This brings me to another chilling moment in guitar videos: the fret leveling. Fretwire manufacturing is a precise art with tight tolerances well within the range of good playability. That means if the fretboard is true and all the frets are seated properly, no fret leveling is needed at all. So, when a video is about doing a “fret job” on a brand-new build, you know that something was botched in an earlier step. Fret filing is reserved for compensating for uneven fret wear or impact damage. Of course, if the fretboard radius is sloppy, there’s no way the frets will be level regardless of how you put them in. I roll my eyes when I see a hand router on a plywood fixture used to crown a fretboard. It’s certainly faster than sanding with a radius block or swing fixture, but not nearly as accurate. To be clear, if a router is followed with a more precise shaping process, it’s perfectly acceptable. But you can see that if the first step isn’t right, it’s just kicking the can down the road as everything after that compounds the issue.
Finishing is another area that separates the good from the bad and ugly. A good spray painter is amazing to watch, as they systematically layer smooth and consistent passes over an instrument. You don’t want to see the painter waving the gun around from side to side with a lot of wrist movement like they’re watering a garden. The trick is keeping the speed and distance consistent. When done correctly, clear coats lay out flat and shiny and barely need to be buffed. It takes a long time to learn, but when you get it right, it’s like magic.
There are a lot of great ideas and unconventional yet effective methods to be seen in how-to videos. I’m always happy when I see something brilliant and noteworthy, but occasionally it’s the opposite. Just like the “lessons” that don’t quite get the chords right or ignore the fact that a song was recorded in an open tuning, home-guitar-building videos are not always insight into best practices. That’s doesn’t mean that they can’t be entertaining. So, get out the popcorn and settle in for some luthier jump scares.
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Neil’s brother-in-law Billy’s Ovation, before Neil’s repairs.
Reader: Neil Crump
Hometown: Austin, Texas
Guitar: King of the Road
When his brother-in-law passed away, this reader made it his mission to repair his old damaged Ovation guitar as a gift to his niece.
My brother-in-law passed away in March. He was a talented keyboardist and, in his heyday, played in bands that toured internationally. As a musician, he naturally had a guitar—a 1974 Ovation—and a “friend” put an unauthorized abstract paint job on it. That guitar had an extremely hard life: Its top was broken and the frets were completely worn out. As an aspiring luthier, I took the guitar to repair it then pass it on to his daughter. This proved to be a challenging task as I had never done anything more complicated than a basic setup before and I had few luthier tools.
A heat gun and thin spatula knife worked fine to remove the top and the bridge. I did my best to glue the new top halves together—but that left a visible seam, so I put a herringbone center strip over it (to match the purfling I would install later). I had no radius board, so I just clamped the pre-radiused braces I bought and was quite pleased that the new top did have a radius! Once I felt the bridge was sanded perfectly, I glued it down. I then replaced the plastic nut and saddle with bone. A hot soldering iron got the old frets out without damaging the fingerboard. (That said, next time I will clean those slots out better before installing new frets!)
“This proved to be a challenging task as I had never done anything more complicated than a basic setup before and I had few luthier tools.”
I was happy with my progress until I started routing the purfling channel. I had no workbench, and the concave Ovation body made things a bit awkward. While basically “bear hugging” the body with one arm and holding the router with the other, I heard a faint “pop.” The edge of an X-brace had come loose. I was able to squirt glue into the void with a syringe, but the concave guitar body made a brace jack useless (without fabricating a complicated caul). I removed the phono jack and jammed a pencil into the brace, keeping pressure on it with a rubber band. It worked!
Neil gave the Ovation a new lease on life with his extensive repairs, the end result of which can be seen here.
I also learned the importance of channel depth with purfling—I did lots of scraping to get everything flush. I am pleased with the finished product and my niece is so happy! I also put a new label inside the guitar body, with a dedication to her father on it.
Overall, there are multiple wins on this project. I gave tribute to my brother-in-law, made his daughter happy, and learned enough to build a guitar from scratch.
Two horns? It must be a Bison!
Our columnist links a few memories together to lead us to another obscure guitar model—one he remembers from his childhood and came to acquire as an adult.
Do you have any “click and stick” movies that you love? Like when you are channel surfing and see a movie that you’ve watched a lot, and then just watch it again? Lately, for me, it’s been the 2015 movie The Revenant. It’s a truly brutal tale of survival set in 1820s frontier America. My gosh, that movie just draws me in every time. There’s one scene where the main character goes flying off a cliff while riding a horse! He just sort of falls/rolls through a pine tree and lands in the snow … and he still survives! It’s crazy!
It makes me think about an old childhood friend who lived up the street from me. Jerry and his parents lived in an old house on their grandparents’ large plot of land. On one part of the land there was an old orchard filled with all types of fruit trees and pines, and I remember how we would climb to the top of the pines and just roll ourselves down the side, Revenant style! If you fell the right way, the branches would kind of gently let you down to the next, but if you hit it wrong and got in between the branches, you’d be wrecked. It’s like we enjoyed getting hurt, and, of course, when you’re young, you can snap right back. Ah, the days when pain really didn’t hurt. Now I wake up with injuries, for real.
“The action was way high and the fret ends were sharp. It was basically a painful affair.”
So why am I talking about my click-and-stick movie and stupid childhood escapades? Well, let’s get back to memories of my old friend Jerry. First, the house he lived in was so old that it had real wooden siding, but it hadn’t been painted in forever so the exterior took on a worn, faded, haunted house vibe. Second, his carpet was so tattered that it was being held together with duct tape. Lastly, I remember his dad had a cool, old electric guitar in the living room. His dad would let me play it sometimes, and I remember that it actually hurt to play! The action was way high and the fret ends were sharp. It was basically a painful affair. Not falling-out-of-a-tree painful, but as bad as it comes with guitars. It had the label “Conrad,” and young Frank didn’t realize that he’d be looking for that guitar again one day. I mean, it did have four pickups and lots of knobs and switches!
Made at the old Japanese Matsumoko factory in the ’60s, this Conrad Bison 1233 has four pickups and a 27" scale.
Years later, I would discover that his was a Conrad Bison guitar. The model came in a few different configurations, but the four-pickup design was designated as the 1233. Primarily featuring a lovely sunburst, these Bisons were made at the amazing old Matsumoku factory in Japan and were imported by the David Wexler Company that was based in Chicago. Matsumoku always had a good supply of aged wood, and many of the guitars made there are resonant and built well. The Bisons first appeared around 1966 and had a rather good run into the early ’70s.
Simple volume/tone knobs are paired with preset solo/rhythm switches that power alnico magnets. There’s an on/off switch for each pickup, and the sound really covers all the bases. Thumpy lows and crisp highs are all there. And, the pickups handle fuzz and distortion with ease. The Bisons also came in one- and two-pickup configurations with a normal scale, but the four-pickup ones have a longer, 27" scale, which is common for Matsumoku-made electrics.
So there it is: pain, survival, American frontier, Bison, haunted houses. It all sticks together like a duct-taped carpet. Click and stick, baby!
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