Day 7

So as I explained on Day 6 the guitar mould is out of square and as this is the former for the guitar itself I am going to have to square it off now or I will just create a bigger problem during the build itself.

Out of square guitar mould

Ive got it now I need to make a sanding block which will sand at rightangles using the sides of the mould as a guide.  First of all I need some sanding blocks.

Sanding blocks

The sanding blocks have to be square but I have so many this size I just need to be selective about the ones I use.

Checking sanding blocks for square

The sanding blocks are glued to a piece of sandpaper with a weight placed on top to make sure the sandpaper is flat.

Sanding blocks glued to sandpaper

The idea is to glue a rounded piece of plywood to a flat piece of plywood, this should place the edge of the rounded plywood at right angles to the longer flat piece of plywood and  when sandpaper is placed on this edge it should sand at right angles to the vertical surface being used as a guide.  To make sure the rounded piece of plywood is at right angles to its own faces I have rigged up this jig so I can sand the edge using the sanding blocks prepared above.  The idea is to use the sanding block on its side on the lower piece of plywood and sand the rounded part producing a rounded part which will end up at right angles to the bigger piece.

Jig to sand rounded sanding block at right angles

That didnt work so now a different jig - two long pieces of softwood screwed to another piece of plywood spaced around a nother piece of plywood.  Under the two pieces of plywood is a strip of sandpaper.

Sanding jig number 2

Now the rounded plywood can be sanded - the softwood should keep the wood at right angles to its edges.

Sanding the rounded sanding block using jig 2

 The rounded sanding block is now attached to the longer plywood guide.  Glued and screwed.

Prepared rounded sanding block

The prepared sanding block ready to start being used.

Rounded sanding block ready to use

Now its time to test the block to see if it works by sanding the edges of the mould making sure the longer piece of plywood stays flat against the vertical surface to produce a right angle on the edge.

Re sanding edge of plywood mould

What do you know it worked - I have only done approx 1/6 of 1 hlf of the mould but it works.  Will carry on with the rest next time.

Finished squared off mould

Thats the end of day 7- this took another 6 hours thats 51 hours total so far.