DIY Network

Handmade Guitar, Part 10: The Fingerboard From "Handmade Music" episode DHMM-103

The fingerboard is the part of the guitar used to create notes or chord when the instrument is played.

In this segment of DIY's Handmade Music, luthier Lynn Dudenbostel begins work creating the guitar's fingerboard and frets.

Materials:

Ebony stock
Sanding block
Template for frets
Table saw
Band saw
Double-stick tape
Abalone shell
Rotary tool
Epoxy glue
Straight-edge
Carpenter's pencil
Safety glasses or goggles

Safety Alert: Always wear safety goggles or safety glasses when
working with wood, power-tools, saws, drills, routers, etc.

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Figure A

Fingerboard and Frets

The fingerboard is the part of the guitar used to create notes or chords when the instrument is played. Metal frets are space along the length of the ebony fingerboard.

• To shape the ebony wood for the fingerboard, Lynn uses a sanding block with a 16-inch radius to convert the raw ebony stock to a rounded to a rounded fingerboard blank (figure A).
  
• Once the ebony has been prepared, a table saw fitted with a special 22/1000-inch blade is used to cut kerfs for the frets. A custom template ensures the precise placement of the kerfs in the fingerboard. The template is cut from plexiglass, and is attached to the back of the fingerboard using double-stick tape (figure B).

• Once the template is secured to the ebony, the kerfs for the frests are cut on the table saw using a fence and miter-gauge. An indexing pin assists with making the precision cuts, with the fingerboard oriented face-down on the saw (figure C).

  Figure B

  Figure C

  
  

  Figure D

• Fingerboards are tapered so that they're thin at the nut, and wider at the bridge. Once the kerfs have been cut, a band saw is used to make the cuts necessary to create the taper (figure D).
  
• Another traditional detail originating from vintage guitars is the inlay found on the fingerboards. The carved ornamental pieces (figure E) are made from abalone shells (figure F). Although these pieces can be purchased from luthier-supply shops, Lynn prefers to make his own.

  Figure E

  Figure F

  
  
• After cutting the diamond shapes by hand with a tiny saw, Lynn outlines the shape of each diamond on the fingerboard (figure G).

• He then uses a rotary tool to rout out the tiny diamond outlines on the fingerboard (figure H). Each cut is just deep enough to hold the abalone inlay.

  Figure G

  Figure H

  
  
• Using a mixture of epoxy glue and black dye, Lynn dabs a small amount of the special mixture into each cavity using a toothpick, then submerges the inlays into the mix (figure I). Once it's dry, the epoxy mixture resembles ebony surrounding the inlay.

• A thorough sanding job brings the abalone and epoxy filler flush with the surrounding ebony (figure J).

  Figure I

  Figure J

  
  

  Figure K

In the segment that follows, host Jeff Wilson visits George Gruhn at the world-famous Gruhn Guitars in Nashville to learn more about the quality of vintage guitars. Then, Lynn Dudenbostel begins work fashioning the guitar's neck out of mahogany.

RESOURCES :

Kentucky Thunder
For more information on the band that appeared in DIY's Handmade Music, Kentucky Thunder -- and to hear streaming audio and download samples of their music -- visit the website for Skaggs Family Records, www.skaggsfamilyrecords.com.

Stewart MacDonald's Luthier Supply Shop
Website: www.stewmac.com

Luthier's Mercantile International, Inc.
Website: www.lmii.com

Pioneer Valley Luthier Supply Company
Website: www.pioneervalleyluthier.com

GUESTS :

Lynn Dudenbostel, Luthier
Dudenbostel Stringed Instruments
Knoxville, TN

John Arnold, Luthier
Newport, TN

Ted Davis, Luthier
Loudon, TN