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

Introduction

Lunatic 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.

Lunatic Material List

Item

Component

Quantity

Description



1 Lunatic

Body



1 Lunatic

Neck



Miscellaneous

materials (see

below)

BYO Lunatic

Guitar Kit



Volume pot



Knob



Wire: Audio

Controls

Audio Controls



12 screws 3/8”

Mounting screws

Audio Jack &

Back Plates



2 mounting

inserts/screws

Lunatic

Bridge/Tremblock

TIP: use small interior packing

box to inventory and organize piece parts

Introduction

Lunatic Intro- 6 -



Trem Claw



Springs, 3



Screws, 1 ½”,

Tremolo parts



Arm

Wammy bar



Mounting

plate, 1



Plastic

spacer,1



4 screws, 13/4”

Neck mounting

materials



6 Tuning Pegs



6 Washers



6 Nuts



6 screws, 3/8”

Tuning Peg

materials



Jack



Mounting

screws 5/8”, 2

Output Jack



2 Holders



2 plastic

washers



2 screws, 1”

Strap Holder

materials



Pickup



4 screws, ¾”

Pickups material



Tremolo claw

cover, 1



Volume, 1



Truss rod, 1

Body (back)

Access & truss

rod Covers

Introduction

Lunatic Intro- 7 -



6 strings

Strings



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

Introduction

Lunatic Intro- 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.

Examples of Our Custom Shop Products

Section 2 –Mockup and Fit Check

Lunatic Section 2 - 1 -

Section 2 Contents

2Mockup and Fit Check.......................................................................................................................- 1 -