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#1
Hey guys, this is one of hopefully two challenge builds, but that all depends on how I go for time in the next few months. To start off good luck to the other users entering!

Anyway, I realise this has been done before, it's not a unique idea, but I thought I'd give it a go since the end product is something a bit different. I'm making a puzzle guitar, made out of big ol' puzzle pieces cut from purpleheart, sapele, and pine.



Im sure I'll be buying more materials for this than just whats pictured, but hey this is where I started.

I started off drawing up a puzzle piece in AutoCAD and checked it would all tile togeather niecly, I also the 2d drawing for the guitar, getting an idea how I wanted it to look.







I have the use of a laser cutter so at this stage I programmed and lasered out the template to ensure it would be accurate. From here I cut a new template manually and used the laser cut template to make the master template.



________________________________________

Chur
#2
From here I band sawed the pieces out of the 3 woods, keeping the grain always in the same direction of course! Then routed to shape. Didn't take any photos at this stage but I'm sure you all get the idea.

First piece





And another



End of the first two days



Such a b**tch cutting and routing all these out. Never again will I make a guitar like this.
________________________________________

Chur
Last edited by Lightbluemk2 at Mar 16, 2012,
#3
TRIPLE POST

I also used my dremel to cut small voids into the sides of the pieces as I will be using black tinted epoxy to glue these togeather, as I could never ensure perfect gaps between each piece and the voids will allow more epoxy to be present in the joins



Now for some failures; had plenty of small tear outs routing the curves in all these pieces, the purpleheart especially was prone to it, glue and sawdust fix approach mainly, in worse cases I cut them square and glued in new timber pieces





This one was a right mess



plenty of small square cut offs under the bandsaw at the end of the day!



Also did some experimenting tinting epoxy with graphite powder. My worry here is I don't want the black to seep into the timbers themselves, but I'd like nice black lines around the pieces.

________________________________________

Chur
Last edited by Lightbluemk2 at Mar 16, 2012,
#4
Quad post, should have put some rough specs, still figuring them out but the idea is this:

Body: P/h, sapele, pine
Neck: P/h sapele laminated with super thin pine strips - much like the maple ones on my oliver builds

Elec: 1x Paf hum, 1x single coil, series/split/parallel for the hum, 2x vol, 2x tone, kill switch. Towing with the idea of preamped piezo's

Bridge: Gotoh tom - string through with aluminium tonebar in the rear
Tuners: Gotoh rotomatics
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Chur
#6
Great idea. I was thinking about doing a puzzle guitar, but I was just going to do the top in puzzle. Can't wait to see the finished product.
#8
Do you own a lumber yard or something? That's a bunch of solid wood blocks you got there.


Uhhh, which photo are you referring to? I didn't think I had that much!
________________________________________

Chur
#11
Quote by ethan_hanus
The one with all the chunks off wood just lying on the floor.


If you look at the picture with the scissors handles in it, I think those chunks are probably 1 inch squares on a table
#12
The one with all the chunks off wood just lying on the floor.


Yeah those are all the offcuts from where I cut out the knob part of the puzzle pieces, I cut the edges out square then cut around closer to the edge, 4 per piece makes for a big box of little offcuts I have nothing to do with, might make knobs out of them?
________________________________________

Chur
#13
man I have always wanted to do a jigsaw build but ain't skilled enough with a router to take it on....look forward to seeing this progress.

must get my 100E build started
#14
Did a few more pieces, I'll be glad when they're all done and I won't have to cut out any more. You can see a poor repair job in the middle purpleheart piece, after thickness sanding it should be gone thankfully, the humbucker should be in its place regardless.



Also my test mixing graphite powder with epoxy worked well, after sanding no colour had seeped into the timber, so I'll do it again when I glue the pieces together and should hopefully get nice black lines around the pieces

________________________________________

Chur
#17
Looks really good. As for the epoxy, I would recommend a slow curing, low viscosity epoxy. This way, the epoxy will have time to go between the pieces and the bubbles will have time to rise to the top and pop. I'm experimenting with coloring epoxy myself. I might try graphite powder to see how it does.
#19
Thanks guys,

Ippon not ocd, just a bit of patience.
bghk6581 I agree completely, I'm just going to use less hardener next time and really flood it, let it sink down into the gaps
________________________________________

Chur
#20
Quote by Lightbluemk2
Thanks guys,

Ippon not ocd, just a bit of patience.
bghk6581 I agree completely, I'm just going to use less hardener next time and really flood it, let it sink down into the gaps


What epoxy are you using? If I were you, I would use an epoxy thats made for longer cure times rather than messing with the mix. The mix might not cure all the way if you add less hardener.
#21
You are right about that, I would buy and use a slower hardener, but I don't really need a longer open time, its 4 hour open time in normal conditions, 3-7 days to full cure. Ill be applying it to the edges and placing them together then using a syringe to get right down between the gaps so I'm not really concerned in any way, Any bubbles and so forth on the surface can be drop filled later anyway
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Chur
#22
I wouldn't mess with the mix. I've had only bad experiences with epoxy because apparently I suck at mixing stuff. I tried to fill some pickup cavities with it and it never cured GACK! I finished out the hack with mighty putty (the shit billy mays was on about) and some bondo and it ended up being an awesome sounding guitar! Go figure haha
#23
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If it were me I would've made each piece a different shape like an actual puzzle, then again I'm like the only person in the world that could pay that much attention to minute detail
Endorsed by Dean Guitars 07-10
2003 Gibson Flying V w/ Moon Inlay
2006 Fender All-American Partscaster
SVK ELP-C500 Custom

1964 Fender Vibro Champ
1989 Peavey VTM60

[thread="1166208"]Gibsons Historic Designs[/thread]
#24
That is true, but it was just a bit easier sticking to one shape piece, at least then I was gauranteed it'd all fit!

Sorted my template today, JCG notice the edges of this template, smooth curves, no bumps.

________________________________________

Chur
#26
I like the shape! Original, or did I miss something?
Just call me Julius, J, etc.
Taking an Internet break for a while, will come on when I can.
#27
Quote by Lightbluemk2
That is true, but it was just a bit easier sticking to one shape piece, at least then I was gauranteed it'd all fit!

Sorted my template today, JCG notice the edges of this template, smooth curves, no bumps.



i feel so noticed. yes i do thanks
#28
I like the shape! Original, or did I miss something?


I based it off a guitar shape that I saw once and really liked, and just drew something close to it in CAD, so not reeeaaallly, but kind of!
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Chur
#29
wow nice build
ಠ_ಠ
<|>
/ω\



Tell me what nation on this earth, was not born of tragedy-Primordial
#31
Those top wings could potentially be weak, but if you're careful with tuner placement you should be fine
Epiphone Les Paul Plus Top
Jet City JCA5212RC (SLO Modded)
Ibanez WD7 Wah
Mad Professor Sweet Honey Overdrive
TC Electronic Flashback Triple Delay
TC Electronic Trinity Reverb
#32
I would just put a regular head stock on it. Maybe some 1mm thin puzzle peices over the top?
Gear:

Gibson 2005 Les Paul Standard
Fender Road Worn Strat w/ Noiseless pickups
Marshall JCM 2000 401C
Marshall Vintage Modern 2266
Marshall 1960A cab (Dave Hill from Slade's old cab)
Ibanez TS9DX
EHX Little Big Muff
Freshman Acoustic
#34
make it more banjo'esque, but still puzzley, or do a banjo shape with puzzlepeices over it.
Just call me Julius, J, etc.
Taking an Internet break for a while, will come on when I can.
#35
GABarrie, ProphetToJables, Nowa, you are right, there will be an area of stress concentration around the cut out areas, both in torsion and direct stress, but I'm not too worried about strength; the neck is a 5 piece laminate plus I'll veneer a piece of purpleheart over the headstock. I also found this picture when looking for headstock ideas which I think confirms it's a plausible design

http://www.bas-extravaganza.nl/image.php?id=uplfiles/20_Bassen_B15_Puzzle_4_800x600.jpg

Jason, Thanks, yeah I saw that when I was looking for inspiration/ideas for this build, it was quite a cool build, that really sealed the deal for me wanting to try it
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Chur
#36

I'm keeping an eye on this one.

Quote by Lightbluemk2
Headstock idea?


Cool idea but it could easily break. You'll be alright as long as the tuners aren't in the corners of the piece.
Quote by Axelfox
Reeeeeeeeeeeeeeee

Quote by H4T3BR33D3R
I also have to do that. Cottaging this weekend
#37
Quote by ProphetToJables
I would just put a regular head stock on it. Maybe some 1mm thin puzzle peices over the top?

i would prefer this over your headstock idea, it looks weird and i dont think tuner placement will be easy, but thats just my opinion
#38
If you went with your headstock design I feel that for the ease of tuner placement Steinberger's gearless tuners would be the way to go. I put them on my Gibson a long time ago, and while I wasn't as impressed as I hoped I'd be they're fairly good tuners.

DON'T PANIC! DON'T PANIC!
THEY DON'T LIKE IT UP 'EM!
#39
Progress;

Picked up my neck laminates and glued the neck blank up



Mixed up my black epoxy mix



I covered both edges for each join for the body and stuck them all togeather, and flooded the surface with what epoxy I had left, there's bound to be a few air bubbles and a few gaps around some pieces but nothing I can't drop fill with more epoxy later

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Chur
#40
Today I went at both faces with the electric plane and roughly took off most of the epoxy to expose areas that need more filling, then I just drop filled those with more epoxy mix. Once all thats sorted I'll run it through the thickness sander and take a good couple of mm off each side



In general the black lines between the pieces were pretty good, they arent perfect, but I like it that way, reminds you it's hand made and everyones human



________________________________________

Chur
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