How I make a cf neck

[MPU]

Here's a pictorial of how I make a carbon fiber neck. The neck profile is Rick Toone's patented Trapezoidal neck profile. I have his permission to use this profile for my personal bass so here we go.
First I make an obeche core that is 3mm smaller than the final dimensions. Obeche is very lightweight but still rings like a bell when tapped.

 

[MPU]

Next I laminate 7 layers of 195g plain weave carbon cloth with epoxy over the core.

 

[MPU]

Now this thing sucks... I mean I use vacuum bagging to get air and excess epoxy out of the laminate as well as press it to the form of the core.

 

[MPU]

To speed up the epoxy curing I use a low-tech oven. Car interior heater and styrofoam box. Heated up to 45 deg C.

 

[elgecko]

This thread is VERY cool!

 

[MPU]

After four hours I can release the vacuum pressure and take the neck out of the bag. Surface looks fine and it's ready for trimming next morning. Aimed 1.5mm laminate thickness is spot on. I let it cure overnight in boiler room (temp around 25 deg C).

 

[MPU]

Same 7 layers of cf cloth on the top of the core as well. Some trimming and the neck is ready for filler epoxy layers. Behind is the phenolic fretboard I'm going to use.
At the moment the neck is curing with few coats of epoxy sanded between. I'm hoping to route truss rod cavity this week. I'm going to use dual action truss rod even though this neck is very stiff I want to be able to adjust it if needed.

 

[BassCycle]

Cool stuff!

 

[SDB Guitars]

That's pretty cool. I've always wondered how to do that... Thanks!

 

[Ruckus_Instrmts]

Very nice. I'm planning a composite neck build as well, however I won't be using wood as a core. Any reason why you used plain weave instead of a crow's foot/HS or twill weave? I noticed you utilized a vertical bleed out method, Are you using prepreg?

Do you happen to know what your lay up schedule was?

Also, What is your opinion on Rick's Trapezoidal neck profile?

 

[pilotjones]

Very cool. Not a tutorial I would have expected!

With the casing all around, and with half the fibers running longitudinally, how stiff is that thing? I could imagine putting them on the 45 in order to make it a little less stiff, and more adjustable.

 

[MPU]

Very nice. I'm planning a composite neck build as well, however I won't be using wood as a core. Any reason why you used plain weave instead of a crow's foot/HS or twill weave? I noticed you utilized a vertical bleed out method, Are you using prepreg?

Do you happen to know what your lay up schedule was?

Also, What is your opinion on Rick's Trapezoidal neck profile?

I used plain weave just for looks. It's also a bit easier to handle than twill. This one doesn't twist as easily and I can get nicer, straighter lines with this weave. I thought about foam core but I wasn't sure if it would hold its shape in vacuum press. Obeche is not far from foam anyway. The layers are mostly like the top layer, some layers are a bit angled, maybe 15 deg or something like that. I don't use prepreg, cf is wetted with epoxy before bagging. So far the neck profile feels good. I haven't played anything with this shape so this is a test for the shape.
Marko

 

[MPU]

Very cool. Not a tutorial I would have expected!

With the casing all around, and with half the fibers running longitudinally, how stiff is that thing? I could imagine putting them on the 45 in order to make it a little less stiff, and more adjustable.

It is very stiff. I think I'll make some relief on the fretboard before fretting. Hopefully there will be some adjustability on the neck. After all there's not much needed, just a bit.
Marko

 

[MPU]

It's time for fretboard glueing. I routed 8mm wide cavity for 6mm trussrod and laminated a cf u-beam into it. I also thinned the heel, shaped the fretboard end and laminated the top of the heel with 1mm layer of cf. I'm going to make a bolt-on neck with heel going all the way to MM positioned pickup. For fretboard glueing I used clamps and two thick wooden blanks to make sure there's even pressure and also for keeping the neck straight. Next I'm going to radius the board, trim the board sides and fret it. Then it's ready for a few spray coats of 2K acrylic. Hopefully tomorrow I can show you pics of the neck before fretting.
Marko

 

[MPU]

CF weave filled with epoxy and sanded flat, fretboard glued, radiused and fretted, 5 coats of 2k acrylic sprayed on. Still a bit soft so no pics of the fretboard. Next fret leveling, crowning and polishing and the neck is finished.
Marko

 

[MPU]

And two last pick of the neck. Came out just great. Looks and feels nice, only final sanding with 2000 wet'n'dry and buffing as well as fret finishing to do. Now it's time to make the body.

 

[Ruckus_Instrmts]

Nice job! What or how will you be anchoring the strings on the nut end of the business?

 

[MPU]

Nice job! What or how will you be anchoring the strings on the nut end of the business?

There will be an aluminium head clamp. Not done yet but will do today. This one will be for double ball end strings.
Marko

 

[MPU]

And finished bass. The shape is David King's Meadow, tuner/bridge unit is my custom made aluminium units, pickup is my custom sidewinder style pickup. Swamp ash body with lightly flamed walnut, Tru Oli finish.

Sound clip at Invalid Link Removed
Marko

 

[pilotjones]

Looks great!

Question on the trapezoidal neck: do you play with your thumb only on the back flat, or do you wrap around?