Well, I finished hogging out what I'm going to remove from the neck beam, and sanding w/ 80 grit to remove machine marks and burns. As I said earlier this was more a carving practice exercise than actual significant lightening, but it was fun to do and turned out presentable, so I'm calling it a success. I'll be sure to take some pictures next time I'm back in the garage. There's a couple of spots where I can hit it with a spade bit to remove a bit more wood without affecting the strength of the admittedly WAY overbuilt support, and I’ll do that with a drill press when I get over to my friends shop. The angle grinder carving disc and "chainsaw" disc sure do remove wood in a hurry, but admittedly the chainsaw disc especially makes me more than a little nervous every time I fire it up.
Today I ordered a 7.25" radius West African Ebony fingerboard(!) and an extra block of ebony to try and make a matching nut. International shipping was about as much as the wood, and I was considering all kinds of fancy saws and rasps and planes and measuring tools and yadda yadda yadda to make the most out of my shipping dollars, but I decided to minimize my order to just the wood for two reasons:
- Keeping with the theme of spending as little money as possible on this project, and
- Keeping the build to simple home-owner grade tooling as much as possible.
I'm not intentionally trying to make it harder for myself to do, but I like the idea of it being a bit janky and homebuilt DIY, but also playable. That's the vibe I'm going for, anyway. Also I'd like it to be an achievable project for other aspiring builders out there, like me.
I picked up a couple of cheap files and a Surform pocket plane from Canadian Tire last weekend for about $30-40 total, and I think between that, the angle grinder, and the random orbital sander I'll be able to do the majority of the facet carving on the neck profile. My dad is also looking around his shop for an old hand plane he thinks he has stashed away somewhere. Dads, amiright?
I guess it's time to start thinking about the neck and how hard I want to make this for myself. In the interest of having this completed by July, I'm leaning towards keeping it more on the simple side. I'll need to find some router bits that'll be appropriate for the truss rod and carbon fibre bars I ordered, and get started cleaning up some timber for the neck. And planning the headstock shape, and figuring out the general plan of attack for cutting out the neck shape and tapers. ...not necessarily in that order...
I’ve decided to make use of some 100 y/o Douglas Fir 2x4s I took out of my house, so at least I have that decision made which gives me limiting dimensions to work within. The boards are a gorgeous reddish colour on the aged exterior, and much lighter with a pinkish hue underneath, which I expect will darken nicely when finished.
My main concerns are
- These boards are shockingly heavy compared to today's SPF 2x4s,
- Checking for nails buried in the wood before ruining any saw blades. Especially borrowed saw blades
.
- They are very splintery on the dry outer face.
I got a splinter which broke off under my fingernail when working on the house a few years ago, and I hope to avoid another trip to the doctor. But, this old lumber is also slightly oversized compared to today's boards, and should give me enough material to work with off a single board. That's the intent for now anyway, and dimensionally it seems to jive with some upright bass neck specs I found online.
I also need to address the neck mounting block. At the very least I’m going to clean up the mounting surface as it’s not perfectly true and a little off kilter on one side. The slope is only 2-3 degrees, which explains why the neck angle doesn’t feel right when playing. I’d like to slope it a little more, but playing with the angle of the whole neck beam by changing the lower mount location would mean I dont have to redo the neck mounting holes, which are (or were supposed to be) perpendicular to the face. I also need to balance the angle of the neck with keeping a manageable bridge height.
I’m currently envisioning my first MDF routing fixture to tackle truing up the mounting face

.