Replacing a snapped off headstock
My brother came across a guitar recently for free that's in great shape except the headstock is snapped about 1" above the nut, beyond the fretboard, so the truss rod isn't exposed or anything. It's an acoustic guitar with an angled headstock and the break is just past the volute on the neck.
I've done some woodworking such as routing, reshaping necks for comfort and other basic finish work and he asked me to give it a go. The worst case scenario is he doesn't get a free guitar.
My plan of attack is as follows:
Measure the angle based on the remaining portion of the headstock.
Use a caliper to measure the headstock thickness.
Use a bandsaw to cut the headstock off just at the ridge of the volute.
Get a piece of mahogany and cut a taper from the volute thickness to the final thickness (most likely 1/2" or 5/16") at the top of the headstock.
Rough shape the mahogany, leaving the top flat for proper pressure at gluing.
Drill the mahogany for 3x3 pegs.
Drill down into the existing neck piece to the left and right of where the truss rod is most likely situated with a 1/4" bit, about 1/2" down.
Drill out the mahogany blank and insert 1" long, 1/4" round dowels to hold in place.
Glue the headstock blank on.
Final cut the headstock and carve the taper from the volute.
Position and install tuning machines.
Restring and setup guitar.
If anyone has any suggestions as far as steps I've missed, feasibility of the steps chosen, or tricks to make things easier it would be appreciated, as I've never undertaken this severe a repair before.
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