Rockler ACOUSTIC GUITAR KIT User manual



UNFINISHEDACOUSTICGUITARKIT

BroughttoyoubyRocklerWoodworkingandHardware

TableofContents

IntroductionandOverview.......................................................................................................................2

PartsList....................................................................................................................................................2

Tools..........................................................................................................................................................4

AssemblySteps.........................................................................................................................................4

1. DryFittheNeckJoint....................................................................................................................4

2. FineSandtheBodyandNeck........................................................................................................5

3. MasktheFretboardandSoundhole.............................................................................................5

4. StainandFinishtheNeckandBody(Apply

RosetteDecal)..........................................................7

5. GluetheNecktotheBody............................................................................................................7

6. InstalltheTuningMachines..........................................................................................................8

7. GluetheNutinPlace....................................................................................................................9

8. InstalltheBridge...........................................................................................................................9

9. InstalltheBridgePins..................................................................................................................12

10. InstalltheSaddle.....................................................................................................................12

11. InstalltheStrap

Button...........................................................................................................13

12. OiltheFretboardandBridge..................................................................................................13

13. StringandTuneYourGuitar....................................................................................................14

AdvancedSteps.......................................................................................................................................14

1. FineTunetheNeckJoint.............................................................................................................14

2. FilingtheNuttoMatchtheNeckWidth.....................................................................................15

Resources................................................................................................................................................16



Intro

Welcome

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ocklerWoo

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uitarwillha

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TrussR

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trings–The

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

Tools

 Analuminumstraightedge:18″–36″long

 Painter’smaskingtape

 A guitar mat: Ascrap offoamor oldcarpet to placethe guitar onto protect itwhile you’re

workingonit.

 Woodglue:Titebond®OriginalWoodglueisrecommended

 Razorknife:X‐Acto®,for

example

 Singleedgerazorbladewithhandle:Usedforscraping

 Finishing supplies:Stain(optional) orpaint(optional),clear coat(recommended).Whattype

ofstainorpaintandclearcoatisthebuilder’spreference.

 Sandpaper:100and220gritisrequired,320or400isoptional

 Clamps:

At least one 24″ bar clamp for the neck‐body joint. Two 12″ bar clamps. Three

woodencamclampswithathroatdepthof41/2″–6″areoptional.

 Roundneedlefile

 Electricdrill(ordrillpress)anddrillbits:1/16″,5/64″,3/16″

 Screwdriver(s):

SeveralsmallPhillips

AssemblySteps

1. DryFittheNeckJoint

Thefirststepistocheckthefitofthenecktothebody.Theremaybesomeresidualglueand/or

sawdustleftinthejointremainingfromthemanufacturingprocess.Thisshouldberemovedsothatthe

jointiscleanandsmoothandtherearenogapsbetweentheneck

andthebodywhenthetwoarefitted

together.Ensurethatall3dowelsareinplaceandfitsnugly.Notethatwhenassemblingtheneckand

thebody,thetrussrodthatisattachedtotheneckmustfitthroughtheslotcutinthetopofthebody.

SeeFigure1:NeckJoint.



Figure1:NeckJoint

Atthispointitisalsoagoodideatodoadryrunoftheclampsetupthatwillbeusedwhenthejointis

actuallyglued.Oneclampisneededtoapplypressurefromtheneckheeltothebodyandanother

clampisneededtoapplypressurefrom

thefretboardextensiontothesoundboard(thetopofthe

body).



SeeFigure2:NeckJointClamping.Youmayoptionallywanttocutv‐notchedwoodencaultohelp

provideagoodclampingsurfaceontheneckheel.Besuretouseapieceofscrapwoodandpaddingon

thebottomofthebodytodistributepressureandprevent

scratches.

Fortheadvancedwoodworker,nowisalsoagoodtimetochecktheneckjointalignmentandmake

adjustmentsifneeded.ThisiscoveredintheAdvancedStepssectionoftheins tructions.Note:Neck

jointalignmentissetinthefactorytoa reasonablestandard.Whileattemptingtoadjustit

byhandmay

resultinamoreprecisealignment,itmayalsoresultinapoorlyalignedorweakneckjointifnotdone

properly.

2. FineSandtheBodyandNeck

Inpreparationforapplyingafinish,sandallwoodenpartsoftheguitar.Mostpartsareprobablyready

for220or320gritsandpaper;someareasmightneedslightlycoursergritfirst.Sandingtofinergritis

personalpreference.Oncesandingiscomplete,cleanthewoodenpartsofallsandingresidue

usinga

tackcloth,compressedair,orsomeothermethod.

3. MasktheFretboardandSoundhole

Mostguitarmakersapplyfinishtothebodyandtheneckseparately.Thisiseasierandresultsinabetter

finishthanmaskinglotsofbitsandpiecesandtrying toapplyfinisharoundallthedifferentpartsofthe

guitar.However,theneckandbridgestillneedtobeglued

tothebody.Sincegluebondsbesttowood,

theneckjointandtheareawherethebridgewillbegluedtothesoundboard(thetopoftheguitar)

needtobeconsidered.Throughmaskingorthroughremovaloffinishlaterintheassemblyprocess,

thoseareaswillbebare

woodbeforetheyareglued.

Neckheelclampingcaul

Figure2:NeckJointClamping



Fortheneck,theentirefretboard(fingerboard)mustbemasked.Itismadeofrosewoodwhichhasalot

ofnaturaloilinitandistypicallyleftunfinished

.Neartheendoftheassemblyprocessitwillinsteadbe

protectedwithalightcoatofoil(see“OiltheFretboardandBridge”).Alsomasktheareasoftheneck

thatwillbegluedintheneckjoint(thefaceoftheneckheelandthebottomof

thefretboardthatis

gluedtothetopofthesoundboard).

Forthebody,thereisnoneedtomaskthebridgelocation.Itsfinallocationcan’tbedeterminedexactly

untiltheneckisgluedinplace.Thefinishwillberemovedfromthebridgelocationbeforegluing(see

“Installthe

Bridge”).Attheneckjoint,somemaskingmaybedone,orthefinishcanberemovedlater

beforetheneckjointisglued,dependingonthebuilder’spreference.However,ifstainorsomeother

typeoffinishthatisabsorbedintothewoodistobeused,theneckjoint

areamustbemasked.Oncethe

stainisabsorbedintothewooditcannotbescrapedawaywithoutremovingmuchofthewood,

damagingtheneckjointintheprocess.Tomasktheneckjointonthebody,applymaskingtapetothe

sideoftheguitarattheneck

joint,cuttingholesforthedowels.Thenattachtheneckandusearazor

knifetotrimthetapearoundtheneckheel.Becarefulnottocutthewoodontheheel.Thissame

proceduremaybefollowedfortheportionoftheneckjointonthesoundboard.Alternatively,an



approximateareacanbemaskedbasedonlineslef tfromthemanufacturingprocessor,ifonlyaclear

coatistobeusedonthesoundboard,itcanbeleftunmasked.



Besuretomasktheinsideoftheguitarbody.Theeasiestwaytodothisisbystuffing

somenewspaper

orbrownpackingpaperinsidethesoundhole.

Figure3:VariousExamplesofNeckJointMasking



4. StainandFinishtheNeckandBody(ApplyRosetteDecal)

Oncemaskingiscomplete,theneckandbodyarereadyforfinishing.Whattypeofstainandclearcoatis

appliedispersonalpreference.Actually,stainisoptio nal,butsometypeofclearcoat(lacquer,

polyurethane,acrylic/urethane)shouldbeappliedtothebodyandthebackofthenecktoprotect

the

wood.Asstatedearlier,thefretboardshouldbeleftunfinished

sinceitismadeofrosewood.Thebridge

shouldalsobeleftunfinishedforthisreason.

Therosettedecalmustbeappliedbeforethefinalclearcoatsareapplied.Itisokaytoapplyonecoatof

clearcoattotheguitarbodybeforeapplyingtherosette,butseveralcoats

shouldbeappliedafterward

toensurethatitisprotectedandsealedtothegui tar.

Toapplythedecal,soakitinabowlofwaterforapproximately20–30secondsuntilitstartstoslideoff

thebackingpaper.Slideitontotheguitarbodyaroundthesoundhole,

peelingawaythepaperbacking.

Whileitiswetitshouldslidearoundontheguitarwithslightfingertippressure.Ifitstartstogetstuck

andneedstoberepositioned,dampenyourfingerinthebowlofwaterandwipeitaroundthesurface

ofthedecal.Usea

sponge,cloth,orpapertoweltosmooththedecal,removeanytrappedairbubbles

andremoveexcesswater.Allowthedecaltodryforseveralhoursbeforeapplyingthenextclearcoat.



Oncetheallcoatsoffinishhavedried,removethemaskingtape.

5. GluetheNecktotheBody

Beforetheneckcanbeglued tothebody,thejointhastobeprepared.Roughdryfittingwasdonein

Step1,butnowfinishhasbeenappliedtothebodyandneck.Thatfinishmustberemovedfromthe

neck‐bodyjointforproperglueadhesion(Note:Finishremoval

onsomepartsofthejointmaynotbe

necessaryiftheyweremaskedpriortofinishing).Todothis,inserttheneckintothebody.Holdingthe

neckfirmlyinplace,useasharprazorknifetocarefullyscribealinearoundthefretboardwhereitrests

onthe

topoftheguitarbo dy. Alsoscribealinearoundtheneckheelwhereitmeetsthesideofthe

Beforeremovingairbubblesand

wrinkles

Afterremovingairbubblesand

wrinkles

Figure4:ApplyingRosetteDecalduringClearCoat



guitarbo

cuttheg

Oncethe

thatthe

insideth

thefinish

touseac

removet

scrapeth

willbeu

Nowthat

fretboard

tobothe

practiced

–72hou

6. Inst

Placethe

Iftheyar

totheto

Oncethe

tuningm

throught

machine

holes,m

protrude

ocklerWoo

y.Becarefu

itarbody.

linesarescri

artsjustout

scribelines.

offandthen

hemicalstri

esoftened

finish,taki

derthefret

thefinishis

meetsthet

dsofthe3

in“DryFitt

sfortheglu

lltheTu

sixferrulesi

loose,appl

rimoftheh

ferrulesarei

chines.Rem

hebackofth

hatneedpil

kesureallth

fromthehe

workinga

nottoscrap

ed,remove

idethescrib

Thereareat

usesome1

pertosofte

inish.Which

gcarenott

oardandth

emoved,ap

pofthebod

owels.Now

eNeckJoin

todryonth

ingMac

tothesixh

asmallam

ole.Thenins

nplace(and

ember,ther

eheadstock.

tholesdrill

etuningma

dstockata9

dHardware

ethesideof

theneck.Fir

elinesarep

leasttwoop

0gritsandp

whatevercl

vermethod

marthesur

neckheel.I

lyTitebond

yandtheba

attachthen

”.Removea

isjointbefor

ines

lesinthehe

untofTiteb

rttheferrul

Figure5:G

thegluehas

are3forth

Therewilln

dwitha1/1

hinesareali

0degreean

thefretboar

t,usingmas

otected.No

ionsfordoi

pertosmoo

arcoatwas

isused,bec

oundingare

’soktoleav

oodglueto

kofthenec

cktothebo

yexcessglu

proceeding

dstock.The

ndtothein

e.

uingFerrulesi

dried,ifnec

leftsidean

wbe2smal

″drillbit.W

nedandtha

le.

ortheneck

kingtape,m

thefinish

gthis.Onei

hthesurfac

used,thenu

refulnotto

.Youonly

~1/32″mar

theneckjoi

heelmeets

yandclam

fromthejo

tothenext

maypressf

idetopofth

Place

ssary),turnt

3fortherig

,Phillipshea

henmarking

thehandle

heelortole

skalongthe

ustberemo

tousearaz

afterwards.

esometype

crapetoom

anttoscrap

inaroundt

twherethe

thebody.Be

.Usethecla

intwithada

tep.

tortheyma

holeanda



heneckover

htside.Inse

dscrewsfor

thelocation

foreachtun

theknifesli

scribelines

edfromthe

rbladetos

Anotheropt

ofscrapert

uchwood–

thefinishth

eedges.

bottomofth

suretoappl

pingsetup

pcloth.Wa

bealittlel

erysmalla

andinsertt

tthetuning

achtuning

forthepilot

ingmachine

age8

and

o

area

rape

ionis



nly

at

e

glue

it24

ose.

ount

e

ost



Figure6:InstallingtheTuningMachines



7. GluetheNutinPlace

Using100‐gritsandpaper,lightlysandthenutwhereitwillbegluedtotheneck.Thiswillhelptheglue

adheretothenormallysmoothplastic.Becarefulnottosandareasthatwillbevisibleafterthenutis

installed.ApplyathincoatofTitebondgluetothe

endofthefretboard,putthenutinplace,andclamp.

Onlyasmallamountofglueisrequiredheresincenomechanicalstressisputonthenut;theguitar

stringswillholditinplace.Notethatduetomanufacturingtolerances,thenutmaybeslightlywider 

than

theneck.Ifthatis the case,lookinAdvancedStep,FilingtheNuttoMatchtheNeckWidth.



8. InstalltheBridge

Thescalelengthofthisguitar(thedistancefromthenuttothesaddle )is25‐1/2″.Thatmeasurementis

requiredforproperplacementofthebridgeontheguitarbody.Measure25‐1/2″fromtheedgeofthe

nut(or12‐3/4″fromthe12

fret,itwillbethesamepoint).Placeapieceofmaskingtapeacrossthe

guitarbodyatthispoint.Itiseasiertoputpenorpencilmarksontapethanonclearcoat.Nowlaya

straightedgealongthesideoftheguitarneckandmarkwherethe

straightedgecrossesthetape.Dothe

sameontheothersideoftheneck.Centeredbetweenthosetwolines,and25‐1/2″fromthenut,isthe

Figure7:GluingtheNut inplace



pointatwhichthesaddleslotonthebridgemustbelocated.RefertothediagramsinFigure9:Bridge

PositionMeasurements,forclarificationofthebridgelocation.Also,measurethedistancefromthe

pointwheretheneckjoinsthebodytothefrontcornerofthebridge.Thisdistance

shouldbethesame

onbothsidesofthebridge.Continuemakingmarksonmaskingtapeuntilthebridgecanbeaccurately

placedintheproperlocation,perpendiculartotheneck.Itmightbehelpfultotransfer thecenterpoint

ofthesaddletothefrontofthebridgeusing

asquaresothatitcanbemoreeasilyalignedtomarkson

theguitarbody.Se eFigure8:BridgePositioning.



Bothlinesmustbe

equal

Centerofbridgeand

saddlearealignedto

centeroftheneck

Middleofsaddleslot

is24½

″fromnutor

12¾”from12

fret

Figure9:BridgePositionMeasurements

Figure8:BridgePositioning



Placethebridgeintheproperlocationandholditfirmlyinplacewithonehandandwhileusingthe

otherhandtoscribealineallaroundthebridgeusingarazorknife.Don’tletthebridgeslipwhiledoing

thisandbecarefulnottoaccidentallycutthe

bridge.Thepurposeofscribingthelineistomarkthearea

oftheguitartopwhereclearcoatmustberemovedsoagluebondcanbeachievedonthebridge‐body

joint.



Oncethelineisscribed,removethebridgeandpreparetoremovethefinishinsidethe

scribelinewhere

thebridgewillbeglued.Followtheprocessdescribedin“GluetheNecktotheBody”—mask,scrape,

sand.Oncethefinishisremoved,repositionthebridgeontheguitaranddoadryrunoftheclamp

setup.Ideally,2–3clampsshouldbeused,reachinginside

thebodytothebridgepatch—apieceof

woodinsidetheguitarbodydirectlybelowwherethebridgewillbelocated. Awoodencaulmightbe

neededbetweentheclampand thebridgepatchtoallowtheclampstoextendoverthebracinginside

thebody.Besureto

usepaddingontopofthebridg etopreventtheclampsfromdamagingthebridge.

Ifclampsarenotavailablethatwillreachinsidetheguitarsoundholetothebridge,anotheroption

mightbetousesomethingstiff,likeawoodenstraightedgeorapieceofwood.Laythestraightedgeor



woodacrossthebridgeandthenclampittothesidesoftheguitar.Again,usepaddingtoprevent

damagetothebridgeandguitarbody.Justbecarefulnottoapplysomuchpressurethatthetopofthe

guitarisdeformed.

Onceyou’rehappywithyourclampingsetup,

removetheclampsandlightlysandthebottomofthe

bridgewith100‐gritsandpapertohelptheglueadhere.NowgluethebridgetothebodywithTitebond

usingthesameclampsetupaspracticedearlier.Useadampclothtowipeawayanyexcessglue.Ifthere 

isa

lotofglueexcessglueitmaybedifficulttoseethescribelinemarkingthebridgelocation.Afew

Figure10:PreparingandClampingtheBridgetotheBody



piecesofbluemaskingtapeplacedontheoutside ofthescribelinemightmakeiteasiertoseeduring

theclampingprocess.Theycanberemovedaftertheclampsareset,beforethegluedries.

Allowthegluetodryforatleast24hours.

9. InstalltheBridgePins

Oncetheglueforthesaddlehasdried,itistimetoinstallthebridgepins.Usea3/16″drillbittodrilla

holethroughthebridge,allthewaythroughthetopoftheguitar,ateachofthelocationsalready

markedinthetopofthebridge.Be

suretodrilltheholeperpendiculartotheguitarbody.Afterdrilling,

thebridgepinswon’tfitintheholes.That’sbecausetheholesmustbetaperedtomatchtheshapeof

thebridgepins.Normally,aguitar luthierwoulduseaspecialtoolcalledbridgepinreamerforthis

task.

Amorecommonlyavailableandlessexpensivetoolisaroundneedlefile.Usetheneedlefiletoslowly

enlargethetopofthebridgepinholes,taperingthemtowardthebottom.Keepcheckingthefitofthe

bridgepins.Thebridgepinsshouldfitjustsnuglyandtheyshouldn’t

betooloose.



Figure11:TaperingaBridgePinHole

10. InstalltheSaddle

Lightlysandthebottomofthesaddlewith100‐gritsandpaper.Applyasmallbeadofgluetothebottom

ofthesaddleandplaceitintheslotinthebridge.Becarefulnottogetanyexcessglueonthebridge

andmakesurethebridgeisinsertedinto

theslotfacingtherightdirection(seeFigure12:Saddle

Installation,forproperorientation).Lightlyclamp,oratleasttape,thesaddleinplaceuntilthegluehas

dried.Makesurethesaddleiscenteredinsidetheslotinthebridge.Ifthereisanyplayintheslot,front



toback,itisbettertohavethesaddlecontactingthefrontofthebridge,facingthesoundhole.The

stringswillforceitinthisdirection.



Figure12:SaddleInstallation



11. InstalltheStrapButton

Witha5/64″drillbit,drill aholeintheendoftheguitar,inthemi ddle.Alternatively,a1/16″bitand

slightlyexpandingtheholewillprobablywork.Afterdrillingthehole,screwthestrapbuttonontothe

guitarbody.Besurethefeltbuttonisinplacetoprotect

theguitarfinish.



Figure13:StrapButtonInstallation

12. OiltheFretboardandBridge

Useclothwithasmallamountoflinseedormineraloiltoprotecttherosewoodfingerboard.Besureto

thoroughlycleananyexcessoiloffofthefrets,nut,andsidesoftheneck.Dothesametothebridge

(withthebridgepinsremoved).Commercialfretboardoilsarealsoavailable

atguitarshopsorluthier

supplyoutlets.



Figure14:Onlythe3rdand4thFretsOiledforComparison

13. StringandTuneYourGuitar

Therearemanywaystostringandtuneaguitar.Thissetofinstructionswon’tofferaparticularmethod,

buttheResourcessectionoffersseverallinksontheInternetthatdescribethestringingprocess.There

arealsoreferencesfortuningtheguitar.Electronictunersareavailableatmusicstoresoronline



retailersorevenassmartphoneapplications(alsolistedintheResourcessection).

AdvancedSteps

1. FineTunetheNeckJoint

Whiletheneckisattachedtothebody,itisagoodtimetochecktheneckjointalignment.Theneck

shouldbeperpendiculartothebody(sidetoside)andthefretboardneedstohaveaveryslightangle.

Theseareascanbecheckedwithastraightedgeoracarpenter’s

square.Ideallythesemeasurements

shouldbedonewiththeneckclamped tothebody.Inthefollowingfigures,notethattheclampshave

beenremovedinthepicturesforclarity.

Checkthattheneckisperpendiculartothebody bymeasuringthedistancefromtheendofthe

fretboardto

thesideoftheguitarbody.Repeatonboththeleftandrightsidesoftheneck.Bothsides

shouldbeapproximatelythesamedistance.SeeFigure15:CheckingtheNeckisPerpendicular



Figure15:CheckingtheNeckisPerpendicular



Checktheneckanglebylayinga24″straightedgealongthemiddleofthefretsonthefretboard.Align

the12¾″markonthestraighte dgewiththe12

fret(theonewith2dots).(Note:12¾″isusedbecause

thescalelength,thedistancefromthenuttothesaddle,willbe25½″.The12

fretisexactly½the

scalelength.Sincewehaven’tgluedthenuttotheneckyet,wecanapproximatethebridgepositionby

measuringfromthe12

fret.)Undertheendofthestraightedge,placethebridge,centeringlefttoright

andaligningtheendofstraightedgeovertheslotwherethesaddlewillgo.Thestraightedgeshouldjust

clearthetopofthebridge.SeeFigure16:CheckingtheNeckAngle.Ifitdipsbelowthe

topofthebridge

orismorethan1/8″abovethetopofthebridge,adjustmentsmayneedtobemadetotheneckheel. 



Tomakeadjustments,useasharpchisel,afile,oracardscrapertoremovematerialfromthe

appropriatesideoftheneckheelto

getthenecktoraiseorlowerasdesired(ormoveleftorright).Itis

criticalthatthefaceoftheneckheelthatmeetsthebodyremainflat.Ifitdoesnot,theneck‐bodyjoint

willnotbeasstrongaspossible.

2. FilingtheNuttoMatchtheNeckWidth

Ifthenutiswiderthantheneckitispossibletofiletheendsofthenutsothatitisthesamewidthas

theneck.Itisbesttodothisbeforethenutisgluedinplacesothattheneckisn’tscratchedbythefilein



theprocess.Filebothsidesequallysothatthestringsdon’tendupoffcenterontheneck.Onlyfilea

littleatatimesothatthenutdoesn’tendupnarrowerthantheneck.



Figure16:CheckingtheNeckAngle

Checkgaphere

12¾″at12

fret



Resources

AcousticRe‐StringingTutorial(video):https://www.youtube.com/watch?v=d5DaSHIID‐sor

http://youtu.be/d5DaSHIID‐s



ChangingSteelStrings(PDF):http://www.taylorguitars.com/sites/default/files/Steel_Restring.pdf



GuitarTuna(guitartunersmartphoneapp):http://ovelin.com/guitartuna/



HowtoTuneaGuitar(webpage):http://www.howtotuneaguitar.org/



Rockler ACOUSTIC GUITAR KIT User manual

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