BYO Guitar Lunatic User manual

Lunatic
Guitar Kit Assembly
Instructions
www.byoguitar.com

Introduction
Lunatic 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
Lunatic Intro- 2 -
Contents
Contents....................................................................................................................................................- 2 -
1 Introduction ......................................................................................................................................- 4 -
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 Pickup.........................................................................................- 2 -
2.4 Check Tremolo Claw Alignment and Fit Check (item #5 on material list).................................- 3 -
2.5 Fit check of the back covers (Fig 2.5.1).....................................................................................- 3 -
2.5.1 Tremolo cover:..................................................................................................................- 3 -
2.5.2 Volume Cover:...................................................................................................................- 3 -
2.5.3 Truss Rod Adjustment Access Cover.................................................................................- 3 -
2.6 Check Strap Pins........................................................................................................................- 3 -
2.7 Check Tuner Alignment.............................................................................................................- 4 -
2.8 Check Output Jack.....................................................................................................................- 4 -
2.9 Mockup and Fit Check complete! .............................................................................................- 4 -
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 -

Introduction
Lunatic Intro- 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 -
4.1 Installing the tuners ..................................................................................................................- 1 -
4.2 Neck Installation .......................................................................................................................- 1 -
4.3 Installing the Strap Pins.............................................................................................................- 1 -
4.4 Installing the Floyd Rose Tremolo.............................................................................................- 2 -
4.5 Install the Pickup.......................................................................................................................- 2 -
4.6 Prep the for the Output Jack, Volume control & wiring ...........................................................- 3 -
4.6.1 Wire color coding/prep.....................................................................................................- 3 -
4.6.2 Soldering the Components ...............................................................................................- 4 -
4.6.3 Final wiring –Volume Control...........................................................................................- 4 -
4.7 Install the Strings.......................................................................................................................- 4 -
4.8 Tremolo Claw Adjustment ........................................................................................................- 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 …Other Hints.............................................................................................................................- 5 -

Introduction
Lunatic Intro- 4 -
Fig 1 Major Components in Your Lunatic 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 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.
TIP: Get some finishing ideas by
visiting BYOGuitar.com and BYO Guitar on Facebook