U.S. Guitar Kits Cutaway User Manual download pdf (Page 7)

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Using the two heavy cardboard body forms (supplied with

the kit) create a guitarmaking form which supports the body

during the early stages of assembly.

First, place two scraps of 3/4" plywood onto the work surface

inside the guitar. This will lift the cardboard form up to make

room for the kerfed linings which will be installed later. Lay

the ﬁrst cardboard piece onto the 3/4" plywood inside the

guitar body.

Next, glue a 1-1/4" tall block of scrap wood onto the card-

board, centered about 4" from the smaller end of the guitar

mold. Then glue a second 1-3/4" tall piece of scrap wood,

centered about 4" from the bottom (larger end) of the guitar

mold. Glue the second piece of cardboard onto them. Now

the two cardboard forms are fastened together with blocks

of wood between them, creating a three-dimensional form

for supporting the guitar sides.

Make a U-shaped waist clamp from 3/4"-thick plywood,

using the waist clamp measurements (illustrated). The

purpose of the waist clamp is to hold the guitar's waist tight

to the inner cardboard mold, maintaining a constant shape

until the back is glued on.

Use a ﬁle to round the two inner edges of the waist clamp

to remove edges and protect the guitar sides.

To start out, install the waist clamp from the back side of

the guitar. (Later, after the top is installed, you'll switch the

waist clamp to the top side) When sliding the waist clamp

on, hold the guitar sides tight against the cardboard form

to keep from cracking the sides. If the ﬁt is too tight, remove

small amounts from each side of the U-shape until the waist

clamp slides snugly onto the waist (but not so snug that it's

hard to remove).

Making a body mold

Rounded

edge

Waist

clamp

3/4"

Blocks:

1-1/4" tall

1-3/4" tall

Corrugated

cardboard

9-1/4"

13-1/4"

Waist Clamp

Made from 3/4"-thick plywood

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U.S. Guitar Kits Cutaway User Manual Page 7

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