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