Alloy Guitars S-Style Guitar Kit User manual

Category
Guitars
Type
User manual
STAssem Version 1.1 30 June 2016
Copyright © 2014, 2015, 2016 Alloy Instruments, Inc.
Alloy Instruments Inc. disclaims all liability, including infringement on proprietary rights, relating to
the use of the information in this document. No license, express or implied, by estoppal or
otherwise, to any intellectual property rights is granted herein.
This material is protected under copyright and trade secret protections.
* Third-part brands and names are property of their respective owners.
Revision Number Release Date Comments
1.0 1 November 2014 Initial release
1.1 10 December 2015 Updated for new model
STAssem Version 1.1 1 30 June 2016
1.0 Welcome and Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. Contacting Us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.0 Prepare for assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. Unpack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2. Tools you will need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.0 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1. Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2. Controls assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3. Clear all screw holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4. Install the Tuning Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.5. Install the Tremolo Claw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6. Install the Neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7. Install The Jack Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.8. Install the Pickguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.9. Install the Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.10. Installing the Strap Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.11. Neck Fine Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.12. Install the strings and initial tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.13. Install the String Trees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.0 Final Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1. Truss Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2. Set the String Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3. Adjust the Intonation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4. Adjust the Nut Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5. Set Pickup Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.6. Adjust The Tremolo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.0 The End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
30 June 2016 2 STAssem Version 1.1
STAssem Version 1.1 1 30 June 2016
1.0 Welcome and Introduction
Thanks and congratulations on your purchase of an Alloy Guitars Kit!
We believe that after you build your first kit, you will be hooked! We hope that you will come back to us for
future kits - perhaps a different model, or a “fancier” kit with better components - or just to try a different
finishing technique.
1.1. Contacting Us
You can contact us by phone, email, on the web, or postal mail:
Alloy Guitars
10940 SW Barnes Rd. #252
Portland, OR 97225
888-214-8314
www.alloyguitars.com
30 June 2016 2 STAssem Version 1.1
2.0 Prepare for assembly.
Get a cup of coffee. Have a snack. Assembling a guitar is a process that takes time, patience, and thought.
It is not to be rushed. You will want to cherish this instrument for years to come, so go slow and be patient.
The assembly process is broken into the following sections:
Unpacking and Parts Review
Finishing
Assembly
Final Setup
Let’s get started. Open the box.
2.1. Unpack
Gently take out and unwrap the body and neck. Place them on a towel or work cloth. Remove all the
hardware and spread on a towel or large work cloth.
Inspect the neck and body for any shipping damage.
The neck should be smooth and ready for final sanding and finishing.
The body should be ready for finish sanding and either sealing, staining, or painting. (You will have
to do finish work on the body and neck. That is half the fun of assembling your own guitar. Make it
yours!!)
Identify all the hardware components. Please see the photos below, but note that some of these photos
may differ slightly from the components that you received.
1.Body
2.Neck
3.Pickguard (Prewired with pickups, controls, and switch).
4.Strings
5.Tremolo Bridge and screws
6.Tremolo claw, 3 springs, 2 Screws
Figure 1 Box Contents
STAssem Version 1.1 3 30 June 2016
7.Back Body Cover
8.Tremolo Arm
9.Tuning Machines (Body, post, washer) X 6
10.Neck Plate, 4 Screws
11.Output Jack and Plate
12.Strap Pins (Pin, Screw, Washer) X 2
13.String Retainer Trees (Trees, Screws, Sleeves) X 2 (Note: sleeves are different heights.)
14.Screws
15.Allen Wenches (1 Small, 1 Medium)
16.Fretboard Radius Guage
17.Alloy Guitars Pick!
If anything is missing or not correct, please contact our customer service department ASAP!
(www.AlloyGuitars.com, 888-214-8314, help@alloyguitars.com)
Figure 2 Body Figure 3 Neck
Figure 4 Pickguard Figure 5 Pickguard Back
30 June 2016 4 STAssem Version 1.1
Figure 6 Strings
Figure 7 Bridge and Mounting Screws Figure 8 Tremolo Claw and Springs
Figure 9 Back Body Cover Figure 10 Neck Plate w/ Screws
Figure 11 Tremolo Arm Figure 12 Tuning Machines
STAssem Version 1.1 5 30 June 2016
Figure 13 Output Jack and Plate Figure 14 Strap Pins
Figure 15 String Retainer Trees Figure 16 Screws
Figure 17 Allen Wrenches Figure 18 Alloy Pick!
30 June 2016 6 STAssem Version 1.1
2.2. Tools you will need
We do everything we can to make building your guitar straight-forward. Besides the materials to finish the
guitar (paint, stain, sealant, etc.) you shouldn’t need anything else that most people don’t already have in
their garages (such as a soldering iron, or saws). Nor do you need to do any exacting measurements that
might make it difficult to get a high quality instrument. You do, however, need a short list of tools and
supplies:
#1 Phillips Screwdriver (small)
#2 Phillips Screwdriver (medium)
Short metal ruler (6”) with 1/32” markings
Needle-nosed pliers
Painters or Masking Tape
Wood Finishing Materials
Bar soap or wax candle
Large towel or work cloth (big enough to lay a guitar on)
10mm socket wrench for tuning machines
1/16” drill bit and drill (only for installing the second string tree, which may not be required)
String Radius Gauge (provided with kit)
Allen wrenches for truss rod and bridge adjustments (provided with kit)
Additionally, you will be much happier and the setup steps detailed belove will be much easier to perform if
you have the following:
•a capo
a chromatic electronic tuner
Figure 19 Tools
STAssem Version 1.1 7 30 June 2016
3.0 Finish
Before you assemble your guitar, we suggest you complete all finishing of the wood components.
Otherwise, you will need to disassemble the guitar before finishing it.
Now... we know that most of you will want to assemble your guitar right out of the box and worry about
finishing it later. And this is OK! Just reverse all the steps in the instructions which follow carefully.
Weather you are going to oil to natural color, stain, paint, or attempt that 3 color sunburst you saw at the
guitar shop, in the end it should be what you want. Our only suggestion is to not bite off more than you can
chew; if this is your first instrument, don’t try to do a fancy 6 layer sunburst finish with custom color tone
mixing. Rather, start simple and plan on doing more instruments in the future. Things only get better with
time and practice.
And we know from personal experience: building the first guitar only makes you want to build another one.
You better start working on your spouse now. There are going to be a lot of guitars in your house.
There are many books, articles, videos, and web sites
dedicated to different ways to finish a guitar. Additionally,
there are a large number of places to buy finishing
materials. Here are a suggestions for places to start:
Books:
Guitar Finishing Step-by-Step
by Dan Erlewine. Dan
is the primary guy at Stewart MacDonald. He has been a guitar tech for decades and is a good
teacher, too.
(http://www.amazon.com/gp/product/0977651908
)
Understanding Wood Finishing
by Bob Flexner. This is truly a deep dive into the art and science of
finishing wood. Great book! http://www.amazon.com/Understanding-Wood-Finishing-HC-
Woodworker/dp/1565235487
Supplies:
Stewart MacDonald. http://www.stewmac.com
A great source for tools and finishing supplies.
Shellac.net. A good supply of different finishes, including Behlen’s line: http://www.shellac.net/
stringed_Instrument_finishes.html
Wudtone. UK company, but they ship internationally. http://www.wudtone.com/
Online:
Search for “guitar finishing” on youtube.com. There are hundreds of videos to watch.
And lastly, be safe. A few warnings:
Many finishing products are flammable and can produce noxious fumes. Always work in well
ventilated areas away from sources of ignition. Wear appropriate mask and respirator gear!
Sanding, polishing and steel wool can produce large quantities of fine dust. You don’t want to be
breathing this material. Wear appropriate mask and respirator gear!
Both finishing (spraying or wiping coats) and sanding/buffing can make a real mess. Make sure
you are working in an area that can handle the fumes, dust, spills and overspray without forcing
you to sleep on the couch!
Alloy Pro Tip
We suggest that you clean out
screw holes with each layer of
finish that you do. This will
make it much easier to find the
holes!
30 June 2016 8 STAssem Version 1.1
4.0 Assembly
Once your guitar body and neck
have the look you desire and is
COMPLETELY dry, it is time for final
assembly. Waiting is tough, but
fingerprints in that otherwise perfect
finish can be hard to live with. And
please be extra patient. Even after
finishes are dry to the touch, they still
need time to cure. If you mount
hardware, pickguards, tuners, etc.
too early, they will stick to the
uncured finish and potentially and damage the finish. Waiting is hard!
4.1. Warnings
Though we aren’t handling explosives here, there
are places that you can get hurt and we need to
give you a few warnings and suggestions.
TAKE YOUR TIME!
As mentioned earlier, you need to protect
your eyes and lungs while doing any of this
work - in particular when doing sanding and
finishing.
Warning - Follow directions for any finishing products. Some of these materials are toxic, produce
noxious fumes or are flammable. Use in well ventilated areas and away from sources of ignition.
You should always wear safety glasses while working on your guitar kit. These protective glasses
should meet the appropriate standards of the American National Standards Institute (ANSI).
We assume that you have basic skills in working with hand tools - screwdrivers, pliers, Allen wrenches,
drills and the like. We assume that you are familiar with the safe operation and use of the various tools
and techniques described i this document. If you are not qualified to do these operations, then you
need to stop building your guitar kit for your own safety.
4.2. Controls assembly
If you received a fully wired guitar kit from us, there isn’t any work to do here - the pickups, volume and
tone controls, and output jack are pre wired with snap together connectors and the pickups are already
loaded into the pickguard. If you received your kit unwired, you will need to prepare the pickguard, pickups,
and controls, including soldering all the connectors. The rest of this manual assumes that this is all
completed.
4.3. Clear all screw holes
It is important to clear all the screw holes prior to assembly. It can be difficult to screw through tough and
durable sealants, such as polyurethane. Additionally, it will be difficult to get everything lined up in the
correct locations. The best way to clear screw holes by hand with a very small drill bit (1/16”).
On front of body:
11 pickguard mounting holes
6 bridge mounting holes
Alloy Pro Tip
“High Scratch Risk Zones!” ahead. The last thing
you want to do is scratch the surface of your
beautiful guitar. You will see “High Scratch Risk
zone!” notations in the remaining instructions. We
recommend placing painters tape on your guitar
in several areas to reduce the chance of damage
caused by screw slips, screwdriver gouges, and
the like. Go slow, be patient!
Alloy Pro Tip
Always think first. Don’t hurt yourself,
or your guitar. Gouges in your wood
grain will not heal. Measure twice, cut
once. If you don’t have experience
using the tools or techniques needed
for assembly, please seek help from
someone who does.
STAssem Version 1.1 9 30 June 2016
2 jack plate mount holes
On the back of the body
6 back cover holes
4 neck mounting holes
2 tremolo pocket screw holes
On the horn and bottom edge
2 strap button holes
4.4. Install the Tuning Machines
There are four parts to each tuner: the tuner itself, a threaded barrel, a washer, and a small screw.
Insert the tuner closest to the neck from behind the head stock. (Figure 20)
Place the washer over the top of the tuner, then insert the barrel into the hole around the tuner. (Figure
21)
Align the tuner screw hole with the hole in the back of the headstock.
Hand tighten the barrel so it stays in place.
Repeat for the other five tuners.
Place a piece of painters tape along the bottom of the tuners to protect the headstock. (Figure 22)
Carefully install the screws into each of the tuner screw holes.
Caution: Do not over tighten. It is very easy to strip the heads of these small screws - or break
them off entirely!
Tighten each of the barrels on the front of the neck until the tuner is firmly in place using a 10mm
socket wrench. If you have deep sockets use them so you have no risk of scratching the tops of the
tuners. (Figure 23)
Twist each of the tuners to ensure it turns smoothly.
Remove the protective tape from the back of the neck and remove any film from the back of the tuners.
Figure 20 1st Tuner Figure 21 Washer and Barrel
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4.5. Install the Tremolo Claw
The claw is held in place using two screws which are
driven into the body and adjusted as needed to control
string tuning, tremolo, and note bending capabilities.
Place the body face down onto a sturdy, soft
workspace.
Ensure the two screw holes are clear and visible at
the front of the cavity.(Figure 24)
Place the claw into the cavity with the screw holes
facing the front and the spring teeth facing the back of the cavity. (Figure 25)
Use a long handled screwdriver so that you are less likely to mar the edge of the tremolo cavity.
Put tape around the back edge of the tremolo pocket to protect the finish while screwing the claw
screws into the body. (Figure 26)
Insert the two screws and drive until about half the threads are visible. They will be tightened more
later. (Figure 27)
The screws should be inside the cavity - below the surface of the guitar so that the cover plate does
not hit them when it is installed (or when you flip the guitar over in the next step). If they are not below
the surface of the guitar, drive them in until the are just clear. (You shouldn’t need to drive them in all
the way!
Leave the tape on for now. We will tighten the screws more in a bit.
Turn the body over and place on its back.
Figure 22 Painters tape and screws installed Figure 23 Tuner with wrench
Figure 24 Tremolo cavity and claw screw holes Figure 25 Claw set in place
Alloy Pro Tip
Tremolo claw screws and Neck
screws are big and long and can
be difficult to drive, even with
pilot holes. To make it easier,
rub the screw threads on the
soap or candle to add a little
non-oil based lubricant.
STAssem Version 1.1 11 30 June 2016
4.6. Install the Neck
Start with the body resting on a sturdy, flat, soft surface.
LOOK AT AND UNDERSTAND THE PICTURES. The neck should only be inserted from the top
, not
from the end. The neck widens as you approach the end, so it not fit into the front of the next slot.
(Figure 29)
Attempting to insert the neck from the end can result in damaging the body and/or neck. (Figure 28)
Ensure the neck sits flat and against the body. The fit will be snug but not tight.
Once the neck is in place, gently turn the guitar over
and lay on its face. Be sure to hold the neck and
body together firmly while you turn the guitar over.
You don’t want to twist the neck as this can damage
the neck or body.
Place the neck plate (with the countersunk holes
facing up) on the neck and align the 4 holes. (Figure
30)
DO NOT USE A POWERSCREWDRIVER!
Screw in one of the 4 body screws into one of the two
holes closest to the end of the next. Do not tightened it all
the way leaving room for the plate to move a bit. (Figure
31)
Screw in the remaining screws. Leave them a tiny bit
loose, too.
When all the screws are in, verify that the plate is aligned
Figure 26 Tape to Protect Body Figure 27 Claw with Screws
Troubleshooting!
If the neck does not fit flat against the body, remove and ensure the neck slot is clean and free of
debris. Ensure the neck is clean and free of debris and finish.
If the neck does not fit into the slot, check the clearance on each side. Sometimes light sanding is
required on the neck to place into the slot. The fit is very snug by design and wood can expand and
contract depending on weather conditions.
If the neck is not fitting , check both the neck and body for any raised grain areas, extra paint or
gloss. (Finish coats may be thicker than you think!)
Using #320 or #400 sandpaper, remove any excess finish that is affecting the neck fit. DO NOT
OVERSAND! FIT SHOULD BE SNUG!
Alloy Pro Tip
This is where caring and
patience really count! If using
an electric screw driver to
install the body screws, stop
well before the end of the screw.
Complete the install by hand
with a good, well fitting
screwdriver.
Alloy Pro Tip
Rub the screw threads on
the soap or candle to add a
little wax. This will help
them go in much more
smoothly.
30 June 2016 12 STAssem Version 1.1
well for all of the holes in the plate. At this point, you can continue the tightening of the screws. All of
the screws should be tightened enough to hold the body and neck together snug, but they should not
be completely tightened down.
Turn guitar over and place on its back.
4.7. Install The Jack Plate
The Jack plate goes in now so that the wires are accessible when installing the pickguard.
Feed the wires (which are hooked into a connector) through the hole in the jack pocket into the control
cavity. (Figure 32 and Figure 33)
Place the Jack Plate onto the body and align the two screw holes.
This is a High Scratch Risk zone! Place painters tape on the body around the jack plate ends. There is
no functional use for the tape. It is there to protect the finish.(Figure 34)
Using a good fitting screwdriver, screw the plate onto body, careful not to over tighten, damage the
screw heads, or stripping the hole.
Figure 28 The WRONG WAY to
insert the neck
Figure 29 The right way!
Figure 30 Neck plate in place Figure 31 Neck Screws
STAssem Version 1.1 13 30 June 2016
Remove any tape used to protect the finish.
4.8. Install the Pickguard
All the electrical connections come together!
Ensure all the pickguard mounting holes in the body are open and clean.
Ensure the pickup wiring is aligned with the slots in the body. (Figure 36) (In contrast, Figure 35 shows
the WRONG way to align the wires.)
All wire connections are done using snap together connectors. While we have had no issues with
these connectors, if you prefer a more traditional connection, you can solder the wires together.
Connect the two conductor
connector from the jack to the two conductor connector on the pickguard.
(Figure 37)
Ensure all the pickguard wires are well managed and aligned with the slots and cavities in the body.
(Figure 36)
Bring the pickguard close to the body.
Feed the single conductor connector through the hole to the back of the body. (Figure 38)
Insert the front of the pickguard under the neck and work the pickups and controls into the appropriate
pockets in the body.
Finish inserting all wires and controls into the body so the pickguard rests flat against the body and
aligns with the neck. (Figure 40)
Note: It may take a few tries to get all the wires and connectors to fit. Be patient, reroute wires as
needed.
Slide the pickguard into the body from the bottom. You may have to slightly bend the pickguard and
slide it in. See Figure 39, Figure 40, and Figure 41.
Carefully screw in 11 screws to hold the pickguard down. Do not over tighten
Figure 32 Wire feed for Jack Figure 33 Wire Fed Through Figure 34 Protective tape
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Install the knob on the pickup selector switch.
Figure 35 WRONG routing of wires Figure 36 Correct routing of wires
Figure 37 Output connector Figure 38 Bridge ground connector
Figure 39 Slide top of
pickguard toward neck...
Figure 40 And let the
pickguard lay flat...
Figure 41 ...before sliding it
into place under fretboard
STAssem Version 1.1 15 30 June 2016
4.9. Install the Bridge
Place the tremolo into the bridge slot in the body. The ‘block’ sits in the body and should have clearance
around it through the body. (Figure 42)
Align the bridge six mounting holes to the six predrilled holes in the body. (Figure 43)
Carefully screw the bridge onto the body by driving screws in the 1
st
and 6
th
holes on the bridge. Do
NOT tighten these screws tight onto the body. Tighten the screws until the bridge just starts to lift off of
the body. (Figure 44)
Back screws off ¼ turn, or just until the bridge sits back onto the body.
Lift the bridge, pivoting on the screws to ensure it rocks smoothly. (Figure 45 and Figure 46)
Insert the remaining 4 screws into the bridge and tighten to the same height as the first two screws.
Again, lift the bridge to ensure it raises and lowers with no issues.
Carefully turn guitar over, and place it face down.
Next, we will install the tremolo springs. This may be difficult to do with your fingers. You can use a set
of needle nosed pliers, but be VERY careful in case the spring slips out of your grip. You don’t want to
scratch the guitar! (Figure 48)
Insert one spring onto the tremolo block. (Figure 47)
Bend the ground wire out of the way.
Carefully stretch the other end around the middle claw hook. (Figure 47)
Caution: Be careful when hooking the spring onto the claw. If the spring slips, it could result in
injury to you or damage to your guitar.
Install the remaining two springs between the claw and the block. (Figure 49)
Drive the claw screws into the body until no threads are showing. The springs should be stretching and
have tension in them. (Figure 50)
Note: At this point the springs are over tightened. This is to aid in setup and will be adjusted
again in the future.
Connect the ground line from the front of the guitar to the ground line in the tremolo pocket and tuck
the wire and connector into the pocket.
Troubleshooting!
If the components will not slide easily into the body, or the pickguard will not sit flat, lift the pickguard
slightly and ensure all wires are in wireways and spaces within the body.
You may have to rearrange the wires several times to get them into body. It can be a tight fit. Be
patient and don’t force the pickguard down as this can bend components and break wires.
30 June 2016 16 STAssem Version 1.1
Carefully turn guitar over and place on work surface.
4.10. Installing the Strap Buttons
This is a very easy step in the process, but definitely in the High Scratch Risk Zone!. Go slow, and be
patient.
Locate the two button holes on the body. One on the end, and one on the top horn. Ensure the holes
are clear of paint and sealer. Use 1/16” bit to manually clear if needed.
Place painters tape around both holes to protect around them. (Figure 51, Figure 52)
Assemble the button, screw and washer. The washer goes between the button and the body. (Figure
53)
Place the guitar vertically and screw the button into the horn.
Figure 42 Underside of Block Figure 43 Bridge aligned with
Holes
Figure 44 Attached with 2
screws, resting on body
Figure 45 Bridge rocks up... Figure 46 ...and down freely Figure 47 First spring
installed
Figure 48 Using Pliers Figure 49 3 springs installed Figure 50 Screws tightened
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Alloy Guitars S-Style Guitar Kit User manual

Category
Guitars
Type
User manual

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