DIY Network

Handmade Guitar, Part 6: Head Block and Tail Block From "Handmade Music" episode DHMM-102

	Andy Leftwich (L) and Cody Kilby (R) of Kentucky Thunder.
	Mandolin player Andy Leftwich.

In this segment of DIY's Handmade Music, luthier Lynn Dudenbostel completes the side pieces and creates the head block and tail block for the custom-built guitar.

Materials:

Rosewood stock
Template
Band saw
Drum sander
Block plane
Cabinet scraper
Chisels, gouges
Mallet
Bending form and spreader
Wood glue
Clamps

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

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• Though the inner surface of the guitar's sides will never be seen or felt once the guitar is assembled, Lynn scrapes and sands the rough spots created during the bending process (figures A and B). The rosewood puckers when it encounters the hot bending iron. The scraper and sanding block are used to counter that process.

  Figure A

  Figure B

  
  

  Figure C

• Once the excess wood has been trimmed away from the sides using the band saw, the sides are placed back into the bending form (figure C).
  
  The "waist" of the guitar is spread using a wooden spreader to ensure a snug fit (figures D and E).

  Figure D

  Figure E

  
  

With the sides placed in the form and set aside, work can begin on the guitar's head block and tail block. Those pieces will be glued to the inside of the guitar and will span the seams created at the top and bottom of the body where the two sides contact. The blocks are made from solid mahogany, the same wood used for these pieces in vintage guitars. Although these pieces can be bought pre-made from luthier-supply shop, Lynn prefers to make his by hand.

• To make the blocks, Lynn makes a series of cuts using the band saw.

• Each piece is then shaped further using a belt sander (figures F and G).

  Figure F

  Figure G

  
  
• Once sanding is complete, Lynn carves out a dovetail joint in the head block using a sharp chisel, some gouges and a mallet (figure H). This joint will connect the guitar's neck to the body.

• Lynn applies wood glue to the head block (figure I), an spreads it evenly.

• With glue applied, the head-block is positioned at the seam at the guitar's top (figure J), clamped in position and allowed to dry.

• The tail block is glued in the same way to the bottom seam.

  Figure H

  Figure I

  
  

  	Figure J
  	Members of Kentucky Thunder create their own brand of handmade music.
  	Mandolin player Andy Leftwich likens the process of songwriting to painting a picture, with each instrument being analogous to a different color.

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