Orchid Neck Construction (Trapezoidal)

A series of photographs detailing trapezoidal neck construction sequence. This is how we got there.

1. Cross section — photo of scale drawing bisecting the neck at the first fret. Not much margin for error, in shaping the neck.

2. Raw materials — 6063-T5 .75" (0.125" wall) aircraft grade aluminum square hollow truss rod. Ebony fretboard. Stacked laminate neck blank.

3. Truss rod fitted — very precise work is necessary because the tolerances are so tight. Glue must be able to "escape" so the truss rod sinks fully into its slot, but we definitely do not want to file through the neck wood to the aluminum. Calipers and a template are essential. NOTE: truss rod extends nearly the length of the fretboard but does not compromise the nut-joint strength. I do not like designs that require channel route under the nut: in such a design the headstock is the weakest point of the instrument, and can snap off under stress.

My design won't.

[EDITOR'S NOTE: Confidential to Alex Lifeson...um, can't promise the joint is Marshall-head-proof. But it just might be. Sorry about your white ES-335. I loved the sound of that guitar.]

4. Pre-glue — Orchid's body, neck blank, fretboard and truss rod, ready to glue.

5. Truss rod glue — fully seat the truss rod, and lock it in place...then...

6. Fretboard glue — ...in the same operation as the truss rod. Note the stacked laminate headstock mated to the stacked laminate neck via a spanish luthier's joint (13 degrees).

7. Neck heel glue — ...again, in the same operation, glue the neck into the body blank. Easier and more efficient to do this all at once. Allow 48 hours drying time, because the next step involves machining the neck.

ORCHID SERIES:

Orchid Design
Orchid (Explained)
Stacked Laminate Neck Construction
Orchid Body
Orchid Neck Construction (Trapezoidal)
Trapezoidal Neck Profile
Skipping Ahead
Purple
Orchid Assembly