Sawdust generator

I’ve had a few requests to post details of the top carving jig which shows up in some of the progress pics of John’s guitar. It’s a simple project to knock together, and makes roughing out a carved top much faster. It’s also an impressively efficient way off spreading wood chips over a large area…

One of the common techniques for roughing out carved top instruments is using routers to cut a ’step’ pattern into the wood. This technique works well, but is pretty nerve wracking (it’s very easy for the router to tip and cut deeper than you want) so I settled on this solution. The pictures should be pretty self explainitary, but questions and suggestions for improvement are welcomed.

Here a shot of the jig with a roughed out top. This was my first test, so the contours are not at final dimension yet - the edges were later thinned down to .25 inch.

carve_with_jig.jpg

The router is suspended about a little over 2.5 inches above a flat workboard, enough height to carve a top glued onto a body for a Les Paul style instrument. The router is attached to the base with 2 M6 machine screws.

At the moment the jig is attached to the workboard with 2 clamps, and is perfectly stable and solid, but ultimately it will be screwed in place. However it’s done, you must be completely condfident it can’t move *at all* - You really don’t want it getting lose and coming to find your fingers…

jig.jpg

The guitar body registers off a wooden guide which runs in the body of the jig. The radius at the end of the guide matches the radius of the cutter in the router; a 1″ dish cutter bit.

This image shows the guide removed from the jig.

jig_with_bearing.jpg

This shows the cutter and guide. The guide is adjusted by sliding and clamping with an F-clamp. In time I’ll add thumbscrews and an adjustment slot to the guide piece.

cutterjpg.jpg

Here’s the body registering off the guide. The depth of cut is adjusted with the router plunge mechanism and depth stop.

With the cutter speed up high, and taking no more than 2mm with each pass there is no tendency for chatter or grabbing, which I think is helped by the rounded edges of the bowl cutter. The steps end up very smooth, though care has to be taken to keep the edge of the body square to the jig, otherwise the width of the rebate created can vary.

The jig is also great for routing binding with a bearing bit.

cutter_with_body.jpg

You can space your contour lines equally, which will create an even stepped surface, but I drew out the curve I wanted to create, and then mapped the steps required to come close to this shape if I removed 2mm each time.

Then, I transferred these measurements to the guide - I line up each mark with the edge of the jig, and drop the cutter 2mm each time.

contour_map.jpg

Here’s the result - hopefully a few minutes with a small carving plane and a spokeshave will get me very close to my final shape. In this shot I’ve planed the neck angle into the top with a jack plane - the jig doesn’t do that bit for you :(

26_roughingout_top.jpg

94 Responses to “Sawdust generator”

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    How’s that job application coming along?

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    The form arrived today. Lots of questions - it’s scary!

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    What job are you going for?

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    Why not do a post about wbw? You can make all our guitars - Think about the exposure! Um…

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    I’m going to apply for a trainee locksmith job. It looks like it might be quite interesting, but the hours are brutal. I almost hope I don’t get it because it’ll only leave me 3 days per fortnight clear, plus a few hours in the evenings. Which would make it a bugger to squeeze in building, rehearsing and any sembalance of a social life.

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  6. Phil Says:

    Saw dust generaotr is cool idea, would it work for doing a les paul carved top? Obviously would have to plane neck angle and pickup plane into it either before or after the saw dust generator.

  7. mullmuzzler Says:

    Hi, Setch! This is mullmuzzler from Project Guitar. Long time since I saw your work, or even visited PG forum… I have a question: Prior to carving the top with this jig, did you angle the body first (the 3 degree angle)? Thanks!

    mullmuzzler | OSSMT

  8. LP maple top 'pre-carve' - My Les Paul Forums Says:

    [...] a router to carve a stepped profile that you then smooth out by hand. You can check it out here: Luthier than thou Blog Archive Sawdust generator I can’t say that it is easy or fast, but if you practice a few times on some scrap wood (I used [...]

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