BYO Guitar Explorer Guitar Kit User manual

Explorer Guitar Kit
Assembly Instructions
WWW.www.byoguitar.com

Introduction
Explorer 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.

Introduction
Explorer Intro- 2 -
Contents
Contents....................................................................................................................................................- 2 -
1 Introduction ......................................................................................................................................- 4 -
1.2 Material Check List....................................................................................................................- 5 -
1.3 Additional tools/materials required: ........................................................................................- 8 -
2 Mockup and Fit Check (Figure 2.0) ...................................................................................................- 1 -
2.1 Fit check the Neck to the Body .................................................................................................- 1 -
2.2 Checking the Pickups, Pickguard and Truss access cover .........................................................- 1 -
2.2.1 Mounting of Pickups & Pickguard (reference Figure 2.0).................................................- 1 -
2.2.2 Truss access cover (Figure 2.2.2-1) ...................................................................................- 2 -
2.3 Checking Electrical wiring and components .............................................................................- 2 -
2.4 Check Bridge assembly (Figure 2.4-1).......................................................................................- 2 -
2.5 Miscellaneous Fit Checks ..........................................................................................................- 3 -
2.5.1 Fit check of the back cavity Cover (Fig 2.5.1-1).................................................................- 3 -
2.5.2 Output Jack .......................................................................................................................- 3 -
2.5.3 Check Strap Pins................................................................................................................- 3 -
2.5.4 Check Tuner Alignment.....................................................................................................- 3 -
3 Finish .................................................................................................................................................- 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 -
4 Assembly ...........................................................................................................................................- 1 -

Introduction
Explorer Intro- 3 -
4.1 Installing the Neck.....................................................................................................................- 2 -
4.1.1 Neck Positioning: Neck Cavity Insertion ...........................................................................- 2 -
4.1.2 Neck Positioning: Centering..............................................................................................- 2 -
4.1.3 Neck positioning: neck angle ............................................................................................- 3 -
4.1.4 Neck Installation: gluing in place ......................................................................................- 3 -
4.2 Installation of the Electronic Components ...............................................................................- 4 -
4.2.1 Installing the Wiring Harness ............................................................................................- 4 -
4.2.2 Install Neck Pickup ............................................................................................................- 5 -
4.2.3 Install the Bridge pickup (Reference Figure 4.2)...............................................................- 5 -
4.2.4 Selector Switch Wiring (Reference Figure 4.2) .................................................................- 6 -
4.2.5 Install the Pickguard and Selector Switch.........................................................................- 6 -
4.3 Installation of the Bridge Components.....................................................................................- 7 -
4.3.1 Installing the Bridge ..........................................................................................................- 7 -
4.3.2 Installing the Tailpiece ......................................................................................................- 7 -
4.4 Installing the Nut.......................................................................................................................- 7 -
4.5 Installing the Tuners & Truss Rod Cover (Figure 4.5-1) ............................................................- 8 -
4.5.1 Installing the Tuners..........................................................................................................- 8 -
4.5.2 Installing the Truss Rod Cover...........................................................................................- 8 -
4.6 Install the Strings.......................................................................................................................- 8 -
4.7 Installing the Strap Pins.............................................................................................................- 8 -
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 Adjusting the Action..................................................................................................................- 3 -
5.3.1 The Nut..............................................................................................................................- 3 -
5.3.2 Bridge Saddle Adjustment.................................................................................................- 3 -
5.4 Pickup Height (Figure 5.4).........................................................................................................- 4 -
5.5 Intonation (Figure 5.5) ..............................................................................................................- 4 -
5.6 …Other Hints.............................................................................................................................- 5 -

Introduction
Explorer Intro- 4 -
Fig 1 Major Components in Your Explorer Guitar Kit
1Introduction
Thank you for purchasing a BYOGuitar.com guitar kit. This kit includes everything you need to build a
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 that 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.
TIP: Get some finishing ideas by visiting BYOGuitar.com and BYO Guitar on Facebook
(http://www.byoguitar.com/gallery/index.html)

Introduction
Explorer Intro- 5 -
1.2 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.
Explorer Material List
Item
Component
Quantity
Description
1
 1 Explorer Body
 1 Explorer Neck
 Miscellaneous
materials (see
below)
BYO Explorer
Guitar Kit
2
 1
Explorer
Pickguard
3
 2 black Alnico V
pickups
 4 mounting
screws
 4 springs
Pickups

Introduction
Explorer Intro- 6 -
4
 20 screws 3/8” +
spare
Mounting
screws for
Pickguard &
Back Plate
5
 Tune-o-matic
bridge
 2 posts
Explorer stop
tail
6
 1 harness w/ 3
potentiometers
Explorer
Wiring
harness
7
 1 stop
 2 posts
Bridge
assembly
8
 1 tone
 2 volume
Explorer
knobs
9
 6 Tuning Pegs
 6 Washers
 6 Nuts
 6 screws, 3/8”
Tuning Peg
materials
TIP: use small interior packing
box to inventory and organize piece parts

Introduction
Explorer Intro- 7 -
10
 1 plate
 2 screws, xx”
Electronics
cover
11
 Jack w/plate
 4 mounting
screws
Output Jack
assembly
(note: jack is
prewired to
harness)
12
 2 Holders
 2 plastic
washers
 2 screws, 1”
Strap Holder
materials
13
 1 String
“Nut”/guide
String Nut
14
 6 strings
Strings
15
 Output Cable
 2 Allen
wrenches
Other
16
 Pickup select
Switch

Introduction
Explorer Intro- 8 -
17
 Truss cover
Cover
1.3 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
Clamps
Wrap (8”) or straw
String or fishing line
(36”)

Introduction
Explorer Intro- 9 -
The remainder of the assembly instruction 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 –Assembly: 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, initial 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
Explorer Section 2(Rev A) - 1 -
Section 2 Contents
2Mockup and Fit Check (Figure 2.0) ...................................................................................................- 1 -
2.1 Fit check the Neck to the Body .....................................................................................................- 1 -
2.2 Checking the Pickups, Pickguard and Truss access cover .............................................................- 1 -
2.2.1 Mounting of Pickups & Pickguard (reference Figure 2.0).................................................- 1 -
2.2.2 Truss access cover (Figure 2.2.2-1) ...................................................................................- 2 -
2.3 Checking Electrical wiring and components .................................................................................- 2 -
2.4 Check Bridge assembly (Figure 2.4-1)...........................................................................................- 2 -
2.5 Miscellaneous Fit Checks ..............................................................................................................- 3 -
2.5.1 Fit check of the back cavity Cover (Fig 2.5.1-1).................................................................- 3 -
2.5.2 Output Jack .......................................................................................................................- 3 -
2.5.3 Check Strap Pins................................................................................................................- 3 -
2.5.4 Check Tuner Alignment.....................................................................................................- 3 -
2Mockup and Fit Check (Figure 2.0)
The following steps will ensure that the base, neck,
tuners, pickups, etc. are properly aligned, wired and that
all screw holes have been drilled.
2.1 Fit check the Neck to the Body
Gently insert the Neck into the neck cavity on the Body –
the fit should be snug to ensure proper alignment when
these pieces are glued during assembly. If the pieces will
not fit or are very tight, lightly sand the neck. If the neck is loose, please call BYO Guitar to resolve the
issue.
2.2 Checking the Pickups, Pickguard and Truss access cover
2.2.1 Mounting of Pickups & Pickguard (reference Figure 2.0)
Mount the selector switch (Item # 16 on parts list) on the pickguard so that the switch action will be
near horizontal when mounted on the body.
1. Position the bridge pickup (item #2 on parts list, with the “B” on it) in the Bridge cavity,
temporarily running the wire through the tunnel to the Electronics cavity.
2. Position the Neck pickup (item #3 on parts list, with the “N” on it) in the neck cavity.
Figure 2.0 Body Cavity Locations

Section 2 –Mockup and Fit Check
Explorer Section 2(Rev A) - 2 -
3. Mount the pickguard so that the matches the contour of the body while aligning the pickups to
be symmetrical with the pickguard. Realign as necessary –then mark the holes.
4. Pre-drill :
a. 2 holes for the pickguard;
b. 2 holes for each pick up;
5. Attach with supplied screws and recheck body & component alignment.
a. If the alignment is correct, pre-drill all
remaining holes.
b. If further adjustment is required, repeat
step #1-4 above.
2.2.2 Truss access cover (Figure 2.2.2-1)
1. Temporarily place the “nut” (Item # 13 on parts
list) in place on the neck.
2. Align the plastic cover (Item # 17 on parts list)
with the Truss access hole.
3. Mark and pre-drill the 3 holes.
2.3 Checking Electrical wiring and components
Your Explorer guitar kit comes with a wiring harness that is ready for installation during assembly of your
guitar (Section 4). Check the harness to ensure that all wiring
remains solidly soldered to each component –re-solder as
required (…if necessary, check Figure 4.2 for wiring color codes).
2.4 Check Bridge assembly (Figure 2.4-1)
The Explorer bridge assembly consists of a “Tune-o-matic”
bridge and a “stop tail piece”, each with 2 posts (Items # 5 & 7
on parts list). Each post is press fit into the body at assembly -
hole alignment will be validated during this step.
1. Partially insert (approximately 1/8”) the “tune-o-matic”
inserts & posts into the holes closest to the neck –install
bridge over the posts.
2. Before checking the stop tail piece, ensure that there is a hole between the lower post mounting
hole and the electric cavity for grounding the bridge.
Figure 2.2.2-1 Truss Cover Alignment
Figure 2.4-1 Bridge Assembly Alignment
CAUTION:
The headstock is thin –do not drill through!!

Section 2 –Mockup and Fit Check
Explorer Section 2(Rev A) - 3 -
3. Partially insert (approximately 1/8”) the “stop tail piece” inserts & posts into the holes furthest
from the neck –install (slide) the stop piece over the posts.
Please call BYOGuitar if there are any issues with steps 1-3 above.
2.5 Miscellaneous Fit Checks
2.5.1 Fit check of the back cavity Cover (Fig 2.5.1-1)
Insert the black cover (item #10 on material list) into the back cavity of the body –the cover typically has
a plastic protective film to avoid scratching. Pre-drill the 2 holes for assembly mounting.
2.5.2 Output Jack
Check for pre-drilled holes (4) for the Output Jack (material list
#11), reference Figure 2.0.
1. If the holes are pre-drilled, skip 2.5.3.
2. Insert Output Jack plate (the jack is part of the pre-
wired harness) in Jack Cavity (Fig 2.0).
3. Mark the holes and drill starter holes with 1/16 drill
bit.
2.5.3 Check Strap Pins
Check for pre-drilled holes for the Strap Pins (item 12 on the material list), reference Figure 2.0. If the
holes are pre-drilled, skip to 2.5.4.
1. Mark the rear Strap Pin hole so that it is approximately 7” from the bottom of the Body, and the
forward Pin approximately 1” above the Neck cavity (see Figure 2.0).
2. Drill starter holes with a 1/16 drill bit.
2.5.4 Check Tuner Alignment
Each tuner consists of the tuner, washer, and a threaded bushing.
The tuners are attached to the headstock with a small wood screw
that attaches between the tuners.
1. Insert tuners, 6 each (item #9 on Material List), into the Neck
Headstock. Ensure that the Tuner shafts are perpendicular
to the Headstock (Fig.2.5.4).
2. Check alignment of set screw holes and tuner base - if
alignment is incorrect or holes are not drilled, mark hole locations and drill starter holes with
1/16 drill bit.
Carefully disassemble the Mockup and move on to the next step: applying the finish to your guitar!
Figure 2.5.4 Tuner Alignment
TIP… the holes may need to be widened with a peghead reamer or a
round file. DO NOT widen the holes too much—the tuners should fit snug
.
Figure 2.5.1-1 Back Body Cover Alignment

Section 3 –Finishing Your Guitar
Explorer 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.
Caution: … the neck is
glued to the body of the Explorer guitar:
ensure that mating surfaces are taped
off to prevent the finish interfering with
the adhesive qualities of the glue.

Section 3 –Finishing Your Guitar
Explorer Section 3- 2 -
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).
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.
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
Explorer Section 3- 3 -
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
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
Explorer 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 –Assembly
Explorer Section 4 - 1 -
Section 4 Contents:
4 Assembly ...........................................................................................................................................- 1 -
4.1 Installing the Neck.....................................................................................................................- 2 -
4.1.1 Neck Positioning: Neck Cavity Insertion ...........................................................................- 2 -
4.1.2 Neck Positioning: Centering..............................................................................................- 2 -
4.1.3 Neck positioning: neck angle ............................................................................................- 3 -
4.1.4 Neck Installation: gluing in place ......................................................................................- 3 -
4.2 Installation of the Electronic Components ...............................................................................- 4 -
4.2.1 Installing the Wiring Harness ............................................................................................- 4 -
4.2.2 Install Neck Pickup ............................................................................................................- 5 -
4.2.3 Install the Bridge pickup (Reference Figure 4.2)...............................................................- 5 -
4.2.4 Selector Switch Wiring (Reference Figure 4.2) .................................................................- 6 -
4.2.5 Install the Pickguard and Selector Switch.........................................................................- 6 -
4.3 Installation of the Bridge Components.....................................................................................- 7 -
4.3.1 Installing the Bridge ..........................................................................................................- 7 -
4.3.2 Installing the Tailpiece ......................................................................................................- 7 -
4.4 Installing the Nut.......................................................................................................................- 7 -
4.5 Installing the Tuners & Truss Rod Cover (Figure 4.5-1) ............................................................- 8 -
4.5.1 Installing the Tuners..........................................................................................................- 8 -
4.5.2 Installing the Truss Rod Cover...........................................................................................- 8 -
4.6 Install the Strings.......................................................................................................................- 8 -
4.7 Installing the Strap Pins.............................................................................................................- 8 -
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 neck
pickups. Remove all of the protective tape from neck and the neck cavity that you might have used
during the Finishing process.
TIP… use a blanket or large towel on your work area to protect your guitars’ finish

Section 4 –Assembly
Explorer Section 4 - 2 -
Bridge Saddle, top view
Figure 4.1.1-3
Figure 4.1.1-1
Distance from Bridge to 12th fret = Distance from 12th fret to nut
Figure 4.1.1-2
Figure 4.1.2-1 Explorer Neck Centering
4.1 Installing the Neck
4.1.1 Neck Positioning: Neck Cavity Insertion
There are a few things to consider when
installing a set neck. First is the position, “in
and out”, of the neck in the body. Second, is
the alignment of the neck with the center line
of the body (Figure 4.1.1-1).
To determine the position of the neck when
inserted into the body, it’s important to
understand where the neck should be located.
The distance from the nut (edge closet to the fingerboard) to the 12th fret is equal to the distance from
the 12th fret to the bridge (Figure 4.1.1-2).
Use the scale length of the neck and the
bridge location to determine the neck
placement. DO NOT simply position the neck
so the heel of the neck is at the back of the
pickup cavity.Typically the neck doesn’t
reach the back of the cavity and should not
be assumed to be the correct neck position.
When measuring from the 12th fret to the
bridge, you want to measure to the saddle on
the high E string. (Figure 4.1.1-3) If the bridge
holes are drilled with compensation (usually the
case on a tune-o-matic bridge) the saddle on the
high E string will be closer to the nut then the
saddle on the low E string.
To ensure proper alignment of the Neck pickup
and the neck, temporarily place the neck pickup in
the cavity and attach with 2 screws (Note: the neck
might have to be started into the neck cavity
before mounting the Neck pickup). When you have
the neck located “in and out”, mark it with a pencil
so you can position it correctly when it is glued and
clamped.
Remove the Neck pickup.
4.1.2 Neck Positioning: Centering
The neck needs to be aligned with the center of

Section 4 –Assembly
Explorer Section 4 - 3 -
the pickup cavities and bridge. This step is the same if you are installing a set neck or a bolt
on neck. It’s important to get the correct neck alignment, as incorrect alignment of the neck results in
the E strings not running parallel to the edges of the fingerboard.
Clamp two straight boards to each side of the neck and use a ruler to align the neck with the center of
the bridge (figure 4.1.2-1). If the bridge holes are already drilled, the center is known. If they haven’t
been drilled, align with the center of the pickup cavities. Once you have located the neck, make a mark
on the heel of the bridge and pickup cavity so you align it when gluing and clamping.
4.1.3 Neck positioning: neck angle
The last thing to check is the neck angle (Figure 4.1.3-1). If the angle is not correct you won’t be able to
get the correct action. With the
neck in the pocket, place a straight
edge on the frets. Push the straight
edge back until it’s over the bridge.
The straight edge should be just over
the bridge (Figure 4.1.3-2).
4.1.4 Neck Installation: gluing
in place
Now that the correct positioning and
angle have been established for
Neck, all that’s left is to glue it in
place. Use yellow wood glue, align
the neck with the marks you’ve
made, clamp in place and allow to
dry. Caution should be used when considering the use of glues that expand as they dry (…such as Gorilla
glue) as they might expand
beyond the seam and damage
the finish.
Figure 4.1.3-1 Understanding Neck Angle
Figure 4.1.3-2 Neck Angle
Tip… You might also consider using painters tape on the finished portions of the neck and
body to protect them from damage during the gluing process.