Converting My First Build to Headless

[Chuck Chill-Out]

Okay, I had this happen in December and now am able to post it. Due to a design flaw, the headstock broke when I was putting it away. Seriously, it was a light bump on the top of the couch, and it pretty much exploded.

My wife wanted me to rebuild it so we can hang it on a wall, but I wanted to make it playable. I mean, it took me a year and a half to build it.
So...

I ordered a headless conversion kit.
It is one of those Chinese made "OVERLORD OF MUSIC" (that's to be said in a gravely metal-band voice. Work with me here...) bridge and nut.

First step, reshape the headstock area to make the nut fit. I think this will be the easiest part of the job.

 

[Chuck Chill-Out]

The second issue will be the bridge itself:

I will need to rout out a pocket for it to lower the string height. Also, it looks like it needs to be angled uphill towards the pickups? If anyone has guidance on this, it is appreciated. I will also need to take care of another item:

Anyone notice the broken screw? Yeah, beginners stupidity. I will need to get that out, as well.

I know that the OVERLORD OF MUSIC bridge is cheap and not the best in manufacturing. I have a solution. A former co-worker has a machine shop at his house and said he would make one out of solid brass at cost. He enjoys making things like this. I will give him these for measurements and pictures and he said he will work on it when he can.

 

[Chuck Chill-Out]

Okay, started to square up the broken headstock to prep for the nut and noticed I was missing part of the bottom side (the left side in the pic):

Found it in two pieces, so, now I am waiting for it to dry before cutting it down to attach it.

 

[Chuck Chill-Out]

A Short time in the shop today, so I cut the section off of the broken headstock and glued it in place.

Stupid camera kept focusing on the box underneath.

Here is a shot from the end. I think after reshaping and installing the nut, it will look better.

 

[Chuck Chill-Out]

Cut down the excess from the piece attached yesterday and noticed that the nut was too low. Cut and shaped a shim out of maple and glued it down today.
Tomorrow, shaping the area to make it purty.

 

[bound'n'blocked]

Will be watching. I remember coming across a listing on Reverb that someone was selling that was a conversion project for a P bass to a headless. I have a neck laying around and have always wanted to give it a try.

I'll be interested to see how this goes.

BnB

 

[Chuck Chill-Out]

Will be watching. I remember coming across a listing on Reverb that someone was selling that was a conversion project for a P bass to a headless. I have a neck laying around and have always wanted to give it a try.

I'll be interested to see how this goes.

BnB

This is a learning experience for me. If it lends any information for you, I've done my part.

 

[CatchaCuda]

Cool! I really want to try this with my ltd. My biggest issue is that I hang my basses on a wall. Hmm. So conflicted!

Good on you for fixing it!

 

[Chuck Chill-Out]

Cool! I really want to try this with my ltd. My biggest issue is that I hang my basses on a wall. Hmm. So conflicted!

Good on you for fixing it!

I built a multiple guitar stand, so I do not need to worry about trying to hang it.

 

[Chuck Chill-Out]

Started to shape the head and drill pilot holes. I realized that the holes in the nut are too small for the supplied screws, so it is either find new black screws or expanding the holes. I'll go with the latter.

Is it wrong of me to enjoying shaping be hand? I can lose track of time.

 

[Chuck Chill-Out]

A mistake from a long time ago. I had a screwhead snap off. Rookie mistake: too all pilot hole. The remaining part of the screw needed to come out before I could even think of routing or chiseling out for the bridge. After some work, et voila! Got that sucker out.
Now I need to sharpen my chisels before I start cutting into this.

 

[Chuck Chill-Out]

Okay, I was thinking how I an going to clear out the area for the bridge. Well, I tried to use my Dremel using a cutting wheel and then chisel out the cavity, but the Dremel doesn't have enough power. I guess I will look at making a routing template and going that route.

Thoughts?

 

[Beej]

Thumbs up to a routing template. I'd probably just make it follow the sides of the bridge right off the end of the bass, making a wider shelf under the tuners. Likely need that finger space.

 

[Chuck Chill-Out]

Thumbs up to a routing template. I'd probably just make it follow the sides of the bridge right off the end of the bass, making a wider shelf under the tuners. Likely need that finger space.

That looks like the easier route. Thanks for the advice.

 

[Chuck Chill-Out]

Okay, I am glad I did not rout...yet.
I found two more broken screws. Using a pick, I decided to double check the holes. Sins of the past (I tried a couple of different bridges until I settled on one).
Using a hammer and chisel, I started to remove wood in the area until I was able to pull one of the broken screws out. I still have one to go.

Test fit:

I am pleased with how it sits in there. I do need to get a router bushing for after I remove the final broken screw.
That will smooth and even everything out.

 

[Chuck Chill-Out]

Okay, after much chiselling and some unkind words (targeted myself for not drilling the pilot hole deep enough) I was able to get the broken screw out.

Now, on to routing. I took a slow and shallow pass into the pocket, then a little deeper.

I need to see what the string height is. I may need to go deeper.

 

[Chuck Chill-Out]

Marked out the area I need to rout further, for tuner access, but I realize that I need to rout the pocket deeper. I want some flexibility with the saddles. I think they are sitting too high right now, and they do not lower any further.

And after all that yesterday, I had to take a break:

Apologies, no gratuitous adult beverage shot.

 

[Chuck Chill-Out]

Well, it is not pretty, but I got the pocket deep enough:

Maybe it is too low, but I can raise the saddles to a better height.
Routed out a section to access the tuners:

Now to clean up the pocket, add finish to the area that is visible. Maybe I'll make the tuner pocket a little deeper.
Other things I need to do is find a new place for the strap nut and sand and finish that stupid router bite seen in the last picture. My stupid mistake.
Oh, this was today's woodshop musical selection:

 

[Chuck Chill-Out]

Nut installed. I had to drill out the holes for the screws, they were too small.

 

[Chuck Chill-Out]

I realized today that the Tung Oil I used on this build is still at my friend's woodshop. I guess I'll be making a trip tomorrow or sone day this week.