BYO Guitar JEM User manual
Introduction
JEM Intro- 1 -
Warning
These instructions assume that you are familiar with the safe operation and use of woodworking
machinery and woodworking tools, and understand the techniques used to assemble this project. If you do
not qualify for both of these criteria, STOP building this project for your own safety. Read and understand
the owner’s manual for the machinery you intend to use, take a woodworking class or visit your local
library for more information. Woodworking machinery and tools are inherently dangerous because they
use sharp edges that can and will cause serious personal injury including amputation and death. Do not
underestimate the ability of these tools and machinery to cause injury. Never operate any tool without all
guards in place and always wear approved safety glasses. For your own safety, please heed this warning.
Warning
Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses are
not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American
National Standards Institute (ANSI). Because there are various ways to cut and join wood, you can make
substitutions for the methods stated in this manual. We try to suggest the easiest methods possible.
However, only you know your skills with each piece of machinery. Never compromise your safety by using
a cutting method with which you are not comfortable. Instead, find an alternative approach that will yield
the same result.
Warning
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
Lead from lead-based paints.
Crystalline silica from bricks, cement, and other masonry products.
Arsenic and chromium from chemically treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment,
such as those dust masks that are specially designed to filter out microscopic particles.
California requires the following notice:
Introduction
JEM Intro- 2 -
Contents
Contents....................................................................................................................................................- 2 -
1 Introduction ......................................................................................................................................- 3 -
1.1 Material Check List....................................................................................................................- 5 -
1.2 Additional tools/materials required: ........................................................................................- 7 -
2 Mockup and Fit Check.......................................................................................................................- 1 -
2.1 Checking the Mounting Holes in the Neck................................................................................- 1 -
2.1.1 Drilling Mounting Holes in the Neck (Fig 2.1) ...................................................................- 1 -
2.1.2 Mount the Neck on the Body............................................................................................- 2 -
2.2 The Bridge .................................................................................................................................- 2 -
2.3 Fit check & Alignment of the Pick Guard (…with mounted controls) .......................................- 2 -
2.4 Check Tremolo Claw Alignment and Fit Check (item #5 on material list).................................- 3 -
2.5 Fit check of the Tremolo, Jack (Fig 2.5.1) and Truss Rod Adjustment Cover............................- 3 -
2.5.1 Tremolo cover:..................................................................................................................- 3 -
2.5.2 Output Jack Cover:............................................................................................................- 3 -
2.5.3 Truss Rod cover:................................................................................................................- 3 -
2.6 Check Strap Pins........................................................................................................................- 3 -
2.7 Check Tuner Alignment.............................................................................................................- 4 -
2.8 String Retainer Bar....................................................................................................................- 4 -
2.9 Mockup and Fit Check complete! .............................................................................................- 4 -
3Finish ...............................................................................................................................................- 1 -
3.1 Finish Application Steps ......................................................................................................- 2 -
3.1.1 Solid Color finish: ..........................................................................................................- 2 -
3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish:.......................................- 2 -
3.1.3 Penetrating Stain or water based dye finish: ..........................................................- 2 -
3.2 Explanation of Sequence Steps:..........................................................................................- 2 -
3.2.1 Sanding the Body and Neck.........................................................................................- 2 -
3.2.2 Appling Grain Filler ......................................................................................................- 3 -
3.2.3 Applying Sanding Sealer ..............................................................................................- 3 -
3.2.4 Solid Color Primer.........................................................................................................- 3 -
3.2.5 Burst and Translucent finishes ..................................................................................- 4 -
Introduction
JEM Intro- 3 -
3.2.6 Clear Top coats ..............................................................................................................- 4 -
3.2.7 Buff finish........................................................................................................................- 4 -
4Assembly.........................................................................................................................................- 1 -
4.1 Installing the tuners .............................................................................................................- 1 -
4.2 Output Jack wiring & installation ......................................................................................- 1 -
4.3 Installing the Strap Pins.......................................................................................................- 2 -
4.4 Assemble Pick Guard, Bridge and Neck to Body .............................................................- 2 -
4.4.1 Pick Guard & Controls Installation............................................................................- 2 -
4.4.2 Neck Installation ...........................................................................................................- 3 -
4.4.3 Installing the Floyd Rose Tremolo.............................................................................- 4 -
4.5 Install the Strings ..................................................................................................................- 5 -
4.6 Tremolo Claw Adjustment...................................................................................................- 6 -
4.7 Installing the Strap Pins.......................................................................................................- 6 -
4.8 Installing the String Retainer & Truss Bar Access Cover ..............................................- 6 -
4.8.1 Truss Access Cover........................................................................................................- 6 -
4.8.2 String Restraint .............................................................................................................- 6 -
5 Initial setup .......................................................................................................................................- 1 -
5.1 Adjust the Guitar Neck: Truss Rod............................................................................................- 2 -
5.1.1 Check the Neck..................................................................................................................- 2 -
5.1.2 Adjusting the Truss Rod ....................................................................................................- 2 -
5.2 String Lubrication......................................................................................................................- 2 -
5.3 Re-check the Bridge Alignment.................................................................................................- 3 -
5.4 Adjusting the Action (string height)..........................................................................................- 3 -
5.5 Pickup Height (Figure 5.4).........................................................................................................- 4 -
5.6 Intonation (Figure 5.6) ..............................................................................................................- 4 -
5.7 String Retainer Adjustment.......................................................................................................- 5 -
5.8 …Other Hints.............................................................................................................................- 5 -
1Introduction
Thank you for purchasing a BYOGuitar.com guitar kit. This kit includes everything you need to build a
TIP: Get some finishing ideas by visiting BYOGuitar.com and BYO Guitar on Facebook
(http://www.byoguitar.com/gallery/index.html)
Introduction
JEM Intro- 4 -
Fig 1 Major Components in Your JEM Guitar Kit
complete custom guitar. In addition to the construction of your guitar, you will need to
consider the finish –natural, solid color and possibly a design that will make your guitar unique. We
suggest you do some research to determine your finish preferences. Procuring the required finishing
materials, especially if they have to be ordered, will allow expedite your guitar project.
We carry a full line of finishing products to give you the beautiful finish you are looking for, whether a
clear natural finish or a bold, colorful finish. We also carry an instructional DVD made by Behlen that will
give you step by step instructions to help you achieve the look you want for your custom guitar.
These instructions assume you are familiar with the anatomy of a guitar. Refer to Figure 1 for many of
the terms used in the assembly of your guitar.
Introduction
JEM Intro- 5 -
1.1 Material Check List
In preparation for the building of your guitar, all required material should be checked both for type and
quantity. Use the following check list to ensure all piece parts are included. If you customized your
order (ex. different tuners), ensure that these parts are accounted for. Please contact BYOGuitar if there
are any discrepancies.
JEM Material List
Item
Component
Quantity
Description
1
1 JEM Body
1 JEM Neck
Miscellaneous
materials (see
below)
BYO JEM Guitar
Kit
2
1
JEM Pickguard
with pickups
3
18 screws 3/8”
+ spare
Mounting screws
for Pickguard,
Audio Jack &
Back Plate
4
1
2 mounting
inserts/screws
JEM
Bridge/Tremblock
TIP: use small interior packing
box to inventory and organize piece parts
Introduction
JEM Intro- 6 -
5
Trem Claw
Springs, 3
Screws, 1 ½”,
2
Tremelo parts
6
Arm
Wammy bar
7
4 ferrules
4 screws, 13/4”
Neck mounting
materials
8
6 Tuning Pegs
6 Washers
6 Nuts
6 screws, 3/8”
Tuning Peg
materials
9
Jack
Back access
cover
Output Jack
10
2 Holders
2 plastic
washers
2 screws, 1”
Strap Holder
materials
11
1 retainer
2 screws, ½”
String retainer
materials
Introduction
JEM Intro- 7 -
12
cover
Tremolo cover
13
6 strings
Strings
14
Cover
3 screws
Truss rod cover
15
Output Cable
3 Allen
wrenches
Other
1.2 Additional tools/materials required:
Drill & drill bits
#1 & #2 Phillips
screwdriver
Soldering iron/solder
Masking/painters tape
Finishing/painting
material
Sand paper 220 &
320 grit
Guitar strap
Soap or candle
Feeler gauge
ruler
Wood glue
Wire cutter
Introduction
JEM Introduction - 8 -
The remainder of the assembly instructions is divided into four sections:
Section 2 –Mockup & Fit check: in this section, all components will be checked for proper
alignment and ensure that all holes have been drilled.
Section 3 –Finishing the Body and Neck: after fit check, the components are removed from the
neck & body to allow the selected finish to be applied. This will allow you to customize your guitars’
color(s). As the finishing will likely require several coats with sanding between each coat, ensure that
the finish is completely dry.
Section 4 –Construction: the final assembly is the next step - once the finish has been applied
and completely dried. In this section, all of the components are installed, internal wiring connected and
strings attached –your guitar will ready to go!
Section 5 –Setup: in this section, adjustments are made to your guitar such as the height of the
pickups.
Again, we thank you for your purchase of a BYO Guitar and we look forward to seeing pictures of your
unique guitar! We also look forward to providing you with the guitar for your next project from our
Custom Shop where you can select the wood for the body and neck as well as customizing all of the
other components.
Let us know if your music, school, church or scouting organization would like to undertake a group
project –BYO Guitar can supply multiple kits or custom guitars.
Some Ideas for Finishing Your Guitar and Examples of Our Custom Shop Products
Section 2 –Mockup and Fit Check
JEM Section 2- 1 -
Section 2 Contents
2Mockup and Fit Check.......................................................................................................................- 1 -
2.1 Checking the Mounting Holes in the Neck................................................................................- 1 -
2.1.1 Drilling Mounting Holes in the Neck (Fig 2.1) ...................................................................- 1 -
2.1.2 Mount the Neck on the Body............................................................................................- 2 -
2.2 The Bridge .................................................................................................................................- 2 -
2.3 Fit check & Alignment of the Pick Guard (…with mounted controls) .......................................- 2 -
2.4 Check Tremolo Claw Alignment and Fit Check (item #5 on material list).................................- 3 -
2.5 Fit check of the Tremolo, Jack (Fig 2.5.1) and Truss Rod Adjustment Cover............................- 3 -
2.5.1 Tremolo cover:..................................................................................................................- 3 -
2.5.2 Output Jack Cover:............................................................................................................- 3 -
2.5.3 Truss Rod cover:................................................................................................................- 3 -
2.6Check Strap Pins........................................................................................................................- 3 -
2.7 Check Tuner Alignment.............................................................................................................- 4 -
2.8 String Retainer Bar....................................................................................................................- 4 -
2.9Mockup and Fit Check complete! .............................................................................................- 4 -
2Mockup and Fit Check
The following steps will ensure that the base, neck, tuners,
pickups, etc. are properly aligned and that all screw holes
have been drilled.
2.1 Checking the Mounting Holes in the
Neck
1. Check the neck for pre-drilled (4) mounting holes.
2. Skip to 2.1.2 if the holes are pre-drilled.
2.1.1 Drilling Mounting Holes in the Neck (Fig 2.1)
1. Place the neck in the pocket (…you should be able
to fit the neck in the neck pocket by hand).
a. Make sure the neck is aligned properly with
the pickup pockets.
b. Carefully clamp the neck in place –frets damage easily.
Figure 2.1 Body Cavity Locations
Section 2 –Mockup and Fit Check
JEM Section 2- 2 -
c. Using the 3/32 drill bit, place the bit in the hole through the body and tap it a few times
to make a mark on the neck.
d. Remove the neck from the body.
2. Determine the neck mounting hole depth.
a. Place one of the neck mounting screws with ferrule (item
#7 on material list) through the body into the neck pocket.
b. Measure the amount of the mounting screw that extends
up into the neck pocket, and mark your drill bit.
c. Double check the depth by holding the marked drill bit to
the side of the neck and be certain the drill won’t go
through the fingerboard.
3. Drill the holes in the neck with a 1/8” drill bit. Make sure you don’t
drill through the fingerboard!
2.1.2 Mount the Neck on the Body
Temporarily attach the neck. Use caution, the last thing you want to do is
snap the screw off in the hole!
1. Insert the neck into the neck pocket aligning the mounting holes in
the neck and body;
2. Fasten the Neck & Body with 4 #7 x 1 3/8” screws and ferrules (item
#7 on material list), but do not over tighten them.
2.2 The Bridge
Mounting the Bridge assembly (item 4 on material list) on the JEM guitar utilizes two inserts in the
Bridge Pocket (Fig 2.1) that will be installed in Section 4. When finishing the Body (Section 3), be careful
not to allow finish material into the insert holes.
2.3 Fit check & Alignment of the Pick Guard
(…with mounted controls)
The Pickguard and controls (…volume, tone and pickup
select switch) are supplied as a complete assembly ready for
installation. Check wiring connections to ensure solid solder
joints. Section 4 contains a physical/wiring diagram for any
identified issues. The wiring on the pickguard may need to
be unbundled in order to fit into the channel between the
pickup pockets. Use caution when checking the Pick Guard
as to maintain wiring integrity.
1. Place the Pick Guard assembly into the Control &
Pickup pockets (reference Figure 2.1), temporarily
TIP…a
piece of masking tape
around the drill bit
works great as a depth
indicator.
Figure 2.3 Body Cavity Locations
TIP…to
reduce the chances of
the wood splitting, use
soap or wax on screw
threads
Section 2 –Mockup and Fit Check
JEM Section 2- 3 -
running the Output Jack wiring (…typically blue & black) and the Tremolo ground wire ( …black)
through the respective tunnels (Fig. 2.3).
2. Carefully move the Pick Guard so that it is flush with the top of the Body, while aligned with the
Neck Pocket and the contours of the body. Mark & pre-drill 2 holes in the Body for mounting
the Pick Guard. Using 3/8” screws (item 3 on Material list), attach the Pick Guard (2 screws).
3. After ensuring the alignment of the Body & Pick Guard, mark and drill the remaining Pick Guard
holes with a 1/16” drill bit. Ensure all holes are pre-drilled.
2.4 Check Tremolo Claw Alignment and Fit
Check (item #5 on material list)
Place the Tremolo claw in the back pocket of the Body
(Fig 2.4) ensuring the claw is centered in the pocket.
1. In order to make the assembly process easier,
pre-tin the claw ground point (raised tab in the
center of the claw);
2. Using the claw as a template, mark the hole
positions and pre-drill 2 holes;
3. Start the mounting screws approximately ½” into
the Body –ensure they are centered (Figure 2.4).
2.5 Fit check of the Tremolo, Jack (Fig 2.5.1)
and Truss Rod Adjustment Cover
2.5.1 Tremolo cover:
1. Place cover over Tremolo pocket, pearl finish up
(item 12 in material list);
2. Mark the holes and drill starter holes with 1/16 drill
bit.
2.5.2 Output Jack Cover:
1. Place cover over Output jack pocket, pearl finish up (item 12 in material list);
2. Mark the holes and drill starter holes with 1/16 drill bit.
2.5.3 Truss Rod cover:
1. Place cover over Truss rod access hole (Fig 2.5.3), pearl
finish up (item #14 on material list);
2. Mark the holes and drill starter holes with 1/16 drill bit.
2.6 Check Strap Pins
1. Check for pre-drilled holes for the Strap Pins (item 10 on
Figure 2.4 Tremolo claw Alignment
Figure 2.5.1 Back Body Cover Alignment
Figure 2.5.3 Truss Rod cover
Section 2 –Mockup and Fit Check
JEM Section 2- 4 -
the material list), reference Figure 1.0.
2. If the holes are pre-drilled, skip to 2.7.
a. Mark the rear Strap Pin hole so that it is centered on the Neck/Bridge and the forward
Pin on the most forward point on the top of the Body (see Figure 1.0).
b. Drill starter holes with a 1/16 drill bit.
2.7 Check Tuner Alignment
Each tuner consists of the tuner, washer, and a threaded
bushing (item #8 on material list). The tuners are attached to
the headstock with small wood screws.
1. Insert tuners, 6 each (item #8 on Material List), into
the Neck Headstock. Ensure that the Tuner shafts are
perpendicular to the Headstock (Fig.2.7).
2. Check alignment of set screw holes and tuner base.
3. If alignment is incorrect or holes are not drilled, mark
hole locations and drill starter holes with 1/16 drill
bit being careful not to drill through the headstock.
2.8 String Retainer Bar
The two (2) holes required for the installation of String
Retainer bar (2), Figure 2.8, will be during the guitar final
assembly.
2.9 Mockup and Fit Check complete!
Carefully disassemble the Mockup and move on to the next
step: applying the finish to your guitar!
Figure 2.7 Tuner Alignment
Figure 2.8 String Retainer Bar
Section 3 –Finishing Your Guitar
JEM Section 3- 1 -
Section 3 Contents
3Finish .................................................................................................................................................- 1 -
3.1 Finish Application Steps ............................................................................................................- 2 -
3.1.1 Solid Color finish: ..............................................................................................................- 2 -
3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish:...................................................- 2 -
3.1.3 Penetrating Stain or water based dye finish:....................................................................- 2 -
3.2 Explanation of Sequence Steps:................................................................................................- 2 -
3.2.1 Sanding the Body and Neck ..............................................................................................- 2 -
3.2.2 Appling Grain Filler............................................................................................................- 3 -
3.2.3 Applying Sanding Sealer....................................................................................................- 3 -
3.2.4 Solid Color Primer .............................................................................................................- 3 -
3.2.5 Burst and Translucent finishes..........................................................................................- 4 -
3.2.6 Clear Top coats..................................................................................................................- 4 -
3.2.7 Buff finish ..........................................................................................................................- 4 -
3Finish
Before starting the finish make sure all holes are drilled for any remaining hardware (pickguard, jack
plate, strap pins etc). This section will cover the application of several finish types, including;
1. Solid color
2. Pigmented translucent, gel stain or alcohol dye
3. Penetrating stain or water based dye
The guitar body was sanded at the factory and coated with one coat of sand and sealer. To get a good
finish, the body should be sanded with a series of sandpaper grits up to #320 grit. Apply a solid color
finish, a pigmented translucent finish (Bursts, toners, Blonde, Butterscotch Blonde etc), a gel based stain
or an alcohol based dye finish over the sanding sealer. If you plan on using a penetrating stain or water
based dye, the sanding sealer must be removed.
How you proceed will depend on the finish you would like on your guitar.
The following paragraphs outline several finishing processes, starting with the sequence for a finish type
(paragraph 3.1) followed by detailed explanation of each sequence step (paragraph 3.2).
Caution: if you remove the nut/string tie down from the headstock in preparation for finishing the neck,
tape/cover the mounting area on the neck as to avoid material build-up that might influence the tuning
of your guitar.
Section 3 –Finishing Your Guitar
JEM Section 3- 2 -
3.1 Finish Application Steps
3.1.1 Solid Color finish:
1. Sand the body and neck
2. Apply grain filler if desired.
3. Apply 2 coats of sand and sealer
4. Sand to 320 grit
5. Apply primer
6. Sand the primer
7. Apply color coats
8. Apply clear top coats
9. Buff finish
3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish:
1. Sand the body and neck
2. Apply grain filler if desired.
3. Apply 2 coats of sand and sealer
4. Sand to 320 grit
5. Apply stain or dye
6. Apply clear top coats
7. Buff finish
3.1.3 Penetrating Stain or water based dye finish:
1. Sand the body and neck to bare wood
2. Apply grain filler if desired.
3. Apply stain or dye
4. Apply 2 coats of sand and sealer
5. Sand to 320 grit
6. Apply clear top coats
7. Buff finish
3.2 Explanation of Sequence Steps:
3.2.1 Sanding the Body and Neck
1. Wear a NIOSH-approved respirator and ANSI-approved safety glasses when sanding wood!
2. Before starting the finish on the neck mask off the surface of the fingerboard.
3. Use a flexible sanding block with #150 grit aluminum-oxide sanding paper to sand the guitar
body until there is a consistent scratch pattern on the entire surface. Note: DO NOT round over
TIP… re-open any of the screw holes in the body. Use a toothpick or small drill held between
your fingers to clean out any filler in the holes.
Section 3 –Finishing Your Guitar
JEM Section 3- 3 -
the neck pocket or the body cavities. When hand sanding, always sand in the same direction as
the wood grain.
4. Re-sand the entire guitar body and neck with #220 grit sanding paper and lightly round over the
outside edges of the body.
5. Wipe the guitar body and neck with a damp cloth to “raise" the wood grain.
6. Wait until the wood is dry and re-sand with #220 grit sandpaper to sand the “raised" grain
smooth.
(Note: On a maple fingerboard you can apply a clear finish to the entire neck and fingerboard. Apply
several coats and remove buildup on the frets between coats. An easy way to remove the finish buildup
on the frets is to take a nail and file a half round slot in the head about the same size as the frets. You
can then use this to easily scrape any finish build up.
If the neck has a Rosewood or Ebony fingerboard, be sure to tape off the fingerboard before applying
the finish. Behlen’s Fingerboard Oil is a great product for your fingerboard.)
3.2.2 Appling Grain Filler
Grain filler will fill in the grain and create flat surface. This is essential if you are trying to get a high gloss
finish. Oil based grain filler is recommended. We recommend using Behlen PORE-O-PAC grain filler. For
most finishes use natural colored filler. The dyes used in darker fillers may over time find their way
through the color coat.
Apply the filler by wiping across the grain. You can use a course cloth or your fingers to wipe the grain in.
After it has dried about ten to twenty minutes the excess can be removed with a cloth dampened with
mineral sprits. After about an hour repeat the process and let dry overnight. If you have removed most
of the excess with mineral spirits the remaining filler on the field of the wood can be sanded off (use
#220 again) in a few minutes. It is also a good idea at this time to reopen any of the screw holes in the
body. Use a toothpick or small drill held between your fingers to clean out any filler in the holes. The
body is now ready for a sand and sealer coating.
3.2.3 Applying Sanding Sealer
Sand and sealer is used to give the final coat a level base. It is also helpful in filling scratches which are
too deep to sand out. We recommend using Behlen Vinyl Sealer. This comes in aerosol cans and can
easily be sprayed on.
3.2.4 Solid Color Primer
The last step before applying the color coats is to apply a white primer coat. We recommend using Ohio
Valley Nitro Primer. The white background will also let you apply an opaque color coat with less paint.
Spray on two coats. When dry you may notice that the surface feels rough. Sand off the roughness with
#320 dry and respray. Sand again. If the surface now appears smooth and all grain is opaqued you are
ready for the color coat.
Section 3 –Finishing Your Guitar
JEM Section 3- 4 -
3.2.5 Burst and Translucent finishes
Bursts and Translucent finishes can be applied using aerosol cans of lacquer toner. Ohio Valley Nitro
and Behlen have a full line of Nitrocellulose Lacquer Toners to achieve these finishes.
3.2.6 Clear Top coats
Apply several thin coats of the finish, following the manufacturer's instructions. Multiple thin coats
usually produce a better quality finish than one heavy coat. Dry sand the entire body with #400 grit wet
dry sandpaper after at least three coats of finish have been applied. DO NOT sand through the finish, be
careful on the edges. Use a tack cloth to remove sanding residue. Apply more finish, sanding between
coats, until the finish is the desired thickness.
3.2.7 Buff finish
When the final coat has dried at least a week, preferably a month, remove the masking. Wet sand the
finish using #600 grit wet/dry sandpaper with a sanding block, followed with #1000 grit wet/dry
sandpaper. Use a clean, absorbent rag to remove excess water. Let the guitar dry completely, then use
a tack cloth to remove all residue. Buff the finish by hand or with a buffer, starting with a medium polish
and working up to a high gloss polish.
Note: If you use a buffing machine, be careful to avoid going through the finish, especially on the edges.
Section 4 –Assembling Your Guitar
JEM Section 4 - 1 -
Section 4 Contents
4Assembly ...........................................................................................................................................- 1 -
4.1 Installing the tuners ..................................................................................................................- 1 -
4.2 Output Jack wiring & installation..............................................................................................- 1 -
4.3 Installing the Strap Pins.............................................................................................................- 2 -
4.4 Assemble Pick Guard, Bridge and Neck to Body.......................................................................- 2 -
4.4.1 Pick Guard & Controls Installation....................................................................................- 2 -
4.4.2 Neck Installation ...............................................................................................................- 3 -
4.4.3 Installing the Floyd Rose Tremolo.............................................................................- 4 -
4.5 Install the Strings.......................................................................................................................- 5 -
4.6Tremolo Claw Adjustment ........................................................................................................- 6 -
4.7 Installing the Strap Pins.............................................................................................................- 6 -
4.8 Installing the String Retainer & Truss Bar Access Cover ...........................................................- 6 -
4.8.1 Truss Access Cover............................................................................................................- 6 -
4.8.2 String Restraint .................................................................................................................- 6 -
4Assembly
After your finish has been applied and thoroughly dried, we can now assemble your guitar. In this
section we will permanently install all of the components and solder the wiring for the bridge and pick
guard pickup.
4.1 Installing the tuners
Each tuner consists of the tuner, washer, and a threaded bushing. The tuners are attached to the
headstock with 3/8” wood screws (refer to Section 2.7).
1. Place the six tuners into the holes on the back of the headstock;
2. Slide a washer over the tuner shaft and secure the threaded bushing onto the tuner –do not
tighten yet;
3. Secure the machine heads to the guitar headstock with the supplied screws - tighten the
threaded bushings. Remove the protective film if necessary.
4.2 Output Jack wiring & Installation
TIP… use a blanket or large towel on your work area to protect your guitars’ finish
Section 4 –Assembling Your Guitar
JEM Section 4 - 2 -
Insert the Output Jack (item #9 on the material list) through the
tunnel in the end of the Body; secure with supplied nut (align the
jack contacts to allow for easy soldering prior to tightening).
1. Check the length of the Output jack wires –if they extend
beyond the Body, it may be easier to solder the wires to
the jack prior to inserting in the Body. Ensure that the
wires run through the nut (inside the jack pocket).
2. Solder the signal and ground wires to the jack (see Figure
4.2) (Note: if the signal wire is shielded, solder the shield to
the ground terminal on the jack).
3. Install Output jack cover –pearled surface up.
4.3 Installing the Strap Pins
Secure each strap pins (2) in the pre-drilled holes with the
supplied screws (2ea, 1”).
4.4 Assemble Pick Guard, Bridge and Neck to
Body
Refer to Figure 4.4 during this section. Noted wiring colors are
typical and may vary.
4.4.1 Pick Guard & Controls Installation
1. Check the wiring harness and the integrity of the solder joints, referring to Figure 4.4.1-1 as
required.
reminder…remove the protective film from the Pick Guard, back covers, tuners & pickups
Figure 4.4 Body Assembly Reference
Tip…
if the wires are not red, black & white, the 2 wires soldered to the Volume
potentiometer case are the ground wires; the remaining wire is the signal wire: run the signal & 1
ground wire through the output jack tunnel and the remaining wire through the tremolo tunnel
Figure 4.2 JEM Output Jack wiring
Section 4 –Assembling Your Guitar
JEM Section 4 - 3 -
2. Carefully insert the Pick Guard into the Pickup Pocket (Figure 4.1). Ensure that
the wiring bundle fits in the channel between the pickup pockets:
a) with the Blue & one Black wire (typical) running through the tunnel (Figure 4.4.1-2) between
the Control Pocket and the Jack Pocket, and
b) with the black ground wire (typical) running through the tunnel (Figure 4.4.1-2) between the
Control Pocket and the Tremolo Pocket in the
back of the Body.
c) Seat the Pick Guard –gently pulling the wires
to ensure they are through the tunnels.
d) As done in the Mock up (Section 2.3), carefully
move the Pick Guard so that it is aligned with
the Neck Pocket and the contours of the body.
Using 3/8” screws (item 3 on Material list),
attach the Pick Guard.
4.4.2 Neck Installation
1. Insert the neck into the neck pocket, aligning the mounting holes in the neck and body;
Figure 4.4.1-2 Body Wiring
Figure 4.4.1-1 JEM Wiring Diagram
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