Les Plywood

Les Plywood
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Primary Contact	{{{primary}}}
Created	21/12/2018
Completed	{{{completeddate}}}
Dormant	{{{dormantdate}}}
Version	{{{version}}}
Members	danspencer101
Manufacturer	{{{manufacturer}}}
Model	{{{model}}}
Location	[[{{{location}}}]]
GitHub / Repo	{{{repo}}}
Status	In Progress
Type	Undefined
Live Status	{{{livestatus}}}
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Intro

Can a Les Paul guitar be produced through laser cutting? Probably, yes but anyone who knows anything about guitars would ask why... Well, I wanted to give this a go for no real reason other than its something to do that will challenge my skills. I am under no illusions that plywood is not an ideal material for an electric guitar but I'm going to try it anyway!

Step 1 - CAD

Model in Fusion 360

First things first I needed a model to create the DXF files for the laser cutter. I used a reference image that I found online and modelled it up in Fusion 360. See Here for the reference I used. I have deviated slightly from the plan as it is very badly drawn and doesn't follow any engineering standards at all. Anyway, it was good enough for me to put together a model :)

CAD Model

Once I had the model in Fusion 360 I produced a stack of planes that intersected the model and put a blank sketch on each of these planes. I then named all of the sketches to DXF Sketch 1 through to 8 as shown in the image. To pick up the geometry of the model you need to do an intersect in the sketch, its not automatic as I first thought. Then right click the sketch and save to DXF.

Arrange in Inkscape

With the DXF stack ready I then moved over to inkscape. Importing the sketches one at a time (Making sure to check that I was working in mm) and arranging them onto the 800mmx600mm page resulted in something that looks like this. These can then be taken over to Lasercut5.3 via any method you prefer.

Step 2 - Laser Cutting

I took a couple of videos and have uploaded them to youtube. See below.

Apologies about the vertical video, what was I thinking!

Step 3 - Gluing

Alignment

I put some through going 5mm holes into the model for aligning the stack. I used M5 machine bolts and am hoping to be able to unscrew them once the glue has dried. This alignment method has worked quite well but hasn't resulted in a perfectly smooth external surface. Oh well, the imperfections can be sanded away and any that remain will just add character. The very top layers were aligned using 10mm dowels in the holes where the bridge will go. Seemed to work ok!

Stack

Stack

Clamping Arrangement

Stage 1

Clamping Arrangement

Stage 2

Clamping Arrangement

Result

• 
  Electronics Pocket
• 
  Pickup Selector Pocket
• 
  Flat Top (Note this picture was taken before I glued on the curve top layers)
• 
  With the curve top on
• 
  Another with the curve top on

Step 4 - Sanding the body

I hadn't originally intended to sand this at all but the edges were just a bit too rough due to the misalignment between layers and it didn't feel nice to hold so my hand was forced. The top was sanded using the mouse/ palm sander in the dusty area. I wanted to maintain the layered look of the laser cut layers so didn't go over the top; just broke the sharp edges.

For the edges I used a combination of the disk sander and a drill mounted drum sander, both inside the dusty area. This worked well and has made the guitar nicer to hold whilst maintaining the characteristic layered effect of the ply.

• 
  Layers easily visible on the Edge but overall quite smooth
• 
  Top View
• 
  Back View
• 
  Curve Top

Step 5 - Building the neck

Still unsure how I want to do this.

I'd like to do it on the laser with ply and a veneer on top for the fret board but need to get my CAD model in order before I start this.