BYO Guitar SG Guitar Kit User manual

SG Guitar Kit Assembly
Instructions
WWW.byoguitar.com

Introduction
SG Intro (- 1 -)
California requires the following notice:
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
SG Intro (- 2 -)
Contents
Contents....................................................................................................................................................- 2 -
1 Introduction ......................................................................................................................................- 2 -
1.1 Material Check List....................................................................................................................- 3 -
1.2 Additional tools/materials required: ........................................................................................- 5 -
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.
Fig 1 Major Components in Your SG Guitar Kit
TIP: Get some finishing ideas by visiting BYOGuitar.com and BYO Guitar on Facebook
(http://www.byoguitar.com/gallery/index.html)

SG Intro (- 3 -)
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.
SG Material List
Item
Component
Quantity
Description
1
 1 SG Body
 1 SG Neck
 Miscellaneous
materials (see
below)
BYO SG Guitar
Kit
2
 1
SG Pickguard
3
 2 black pickups
 8 mounting
screws
Pickups
4
 11 screws 3/8”
Mounting screws
for Pickguard &
Back Plates
5
 Tune-o-matic
bridge
 2 posts
SG tailpiece
TIP: use small interior packing
box to inventory and organize piece parts

SG Intro (- 4 -)
6
 1 harness w/ 4
potentiometers
SG Wiring
harness
7
 1 bridge
 2 posts
Bridge assembly
8
 2 tone
 2 volume
SG knobs
9
 3 Tuning Pegs,
upper
 3 Tuning pegs,
lower
 6 Washers
 6 Inserts,
spacers
 6 screws, ½”
Tuning Peg
materials
10
 1 plate, audio
control
Audio/Electronics
cover
11
 Neck base
cover plate
 4 mounting
screws
Neck cover
12
 2 Holders
 2 plastic
washers
 2 screws, 1”
Strap Holder
materials
13
 6 strings
Strings

SG Intro (- 5 -)
14
 Output Cable
 2 Allen
wrenches
Other
15
 Pickup select
Switch
16
 Truss cover
Cover
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
Clamps
Tie wrap (8”) or straw
String or fishing line
(36”)

SG Intro (- 6 -)
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 –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 & Fit Check
SG Section 2- 1 -
Section 2 Contents
2. Mockup and Fit Check (Figure 2.0)................................................................................................- 1 -
2.1 Fit check the Neck to the Body .................................................................................................- 1 -
2.2 Checking the Pickups, Pick guard and Truss access cover ........................................................- 2 -
2.2.1 Mounting of Pickups & Pick guard (reference Figure 2.2.1).............................................- 2 -
2.2.2 Truss access cover (Figure 2.2.2) ......................................................................................- 3 -
2.3 Checking Electrical wiring and components .............................................................................- 3 -
2.4 Check Bridge assembly (Figure 2.4-1).......................................................................................- 3 -
2.5 Check for Bridge Ground Tunnel...............................................................................................- 4 -
2.5.1 Drilling the Bridge Ground Tunnel ....................................................................................- 4 -
2.6 Miscellaneous Fit Checks ..........................................................................................................- 4 -
2.6.1 Fit check of the back-cavity Cover ....................................................................................- 4 -
2.6.2 Fit check Output Jack and Selector Switch Mounting Holes.............................................- 4 -
2.6.3 Check Strap Pins (Figure 2.6.3) .........................................................................................- 5 -
2.6.4 Check Tuner Alignment (Figure 2.6.4) ..............................................................................- 5 -
2. Mockup 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.
The Neck and Body will be glued together in
Section 4, Assembly. Use caution during the Fit
checks as the Neck is not attached to the Body.
Figure 2.0
0 Body Cavity Locations

Section 2 –Mockup & Fit Check
SG Section 2- 2 -
2.2 Checking the Pickups, Pick guard and Truss access cover
2.2.1 Mounting of Pickups & Pick guard (reference Figure 2.2.1)
Locate the following parts in your kit:
Item
Material List
Detail
Pickguard
2
…with 4 screws
Pickups with screws (8 total)
3
Thin taper: Neck pickup
Thick taper: Body pickup
Neck Base guard
11
…with 2 screws
Neck
During this step, the combination of the Pickups, Pickguard and Neck will be aligned so ensure the
correct fitting. Note that the Body is contoured where the Pickups are mounted and should be
considered when marking hole positions.
1. Position the Bridge pickup (item #3 on parts list, with the thicker taper) in the Bridge cavity,
temporarily running the wire through the tunnel to the Audio cavity;
2. Position the Neck pickup (item #3
on parts list, with the thin taper) in
the neck cavity, temporarily
running the wire through the tunnel
to the Audio pocket. Ensure that
the Pickups are flat against the
Body by pulling the individual wires
in the Audio pocket.
(Note: consider twisting the pickup
wires together and running the
combined wire through the tunnel)
3. Mount the pick guard (#2 on
material list) so that the Pickups are
snug in the Pickup pockets and matches the contour of the body while aligning the Pickups to be
centered in the pockets. Additionally, align the neck base cover (#11 on material list) with the
Neck pickup. Insert the Neck to ensure complete alignment. This will require a few times
before the alignment is optimized;
Figure 2.2.1 Body Mounting Locations

Section 2 –Mockup & Fit Check
SG Section 2- 3 -
4. Mark 1 lower hole in each of the Pickups –drill starter holes and partially insert 2 mounting
screws.
a. Check the overall alignment of all components;
b. Realign as necessary;
c. When the alignment is correct, pre-drill all remaining holes: 8 for the Pickups, 4 for the
Pickguard and 2 for the Neck base cover;
d. As a final check, mount all components.
2.2.2 Truss access cover (Figure 2.2.2)
1. Align the plastic cover (Item # 16 on parts list)
with the Truss access hole.
2. Mark and pre-drill the 3 holes.
2.3 Checking Electrical wiring and
components
Your SG 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)
1. The SG 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.
2. Partially insert (approximately 1/8”) the “tune-o-matic”
inserts & posts into the holes closest to the neck –
install bridge over the posts.
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 1-2 above.
Figure 2.2.2 Truss Cover Alignment
Figure 2.4-1 Bridge Assembly Alignment

Section 2 –Mockup & Fit Check
SG Section 2- 4 -
2.5 Check for Bridge Ground Tunnel
In order to minimize audio hum and pickup, the
electrical components are grounded together. This
check ensures that there is a tunnel for routing the
Bridge ground wire to the Bridge mounts. Reference
Figure 2.0 for the layout of electrical component and
wiring –specifically the Bridge Ground wire tunnel, as
shown in Figure 2.5 where a tunnel connects the Bridge
pickup cavity to the Bridge mounting hole. Proceed to
Paragraph 2.6 if there is a tunnel.
2.5.1 Drilling the Bridge Ground Tunnel
As shown in Figure 2.5.1-1, place the Body face up
and locate the lower Bridge Mount hole. Note: use
extreme caution when drilling the tunnel as the
drill can come in contact with the Body causing
damage. Placing material against the drill bit
(white strip in Figure 2.5.1-1) will help protect the
Body.
1. Use a 3/32” drill, pre-dill a starter hole for the tunnel approximately ¼” deep in the Bridge
Pickup cavity into the lower Bridge mounting hole, at 45 degrees;
2. Use a 5/32” drill, at 45 degrees, to complete the drilling of the tunnel so that tunnel enters
the lower Bridge mounting hole;
3. Run a small piece of wire through the tunnel to ensure there is no blockage.
2.6 Miscellaneous Fit Checks
2.6.1 Fit check of the back-cavity Cover
Insert the black cover (item #10 on material list) into the Audio control pocket of the body –the cover
typically has a plastic protective film to avoid scratching. Pre-drill the 4 holes for assembly mounting.
2.6.2 Fit check Output Jack and Selector Switch Mounting Holes
1. Insert and ensure proper fit of the Selector switch (item #15 on material list) into the respective
Body mounting hole (Figure 2.2.1). Enlarge if necessary with a round file;
2. Repeat step 1 with the Output Jack, which is part of the wiring harness.
Figure 2.5 Bridge Ground Wire Tunnel
Figure 2.5.1-1 Drilling the Bridge Ground Tunnel

Section 2 –Mockup & Fit Check
SG Section 2- 5 -
2.6.3 Check Strap Pins (Figure 2.6.3)
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 2.6.4.
1. Mark the rear Strap Pin hole so that it is aligned with
the center of the neck & pickups (Figure 2.6.3), and
the top Pin on the most forward part of the body
above the Neck;
2. Drill starter holes with a 1/16 drill bit.
2.6.4 Check Tuner Alignment (Figure 2.6.4)
Each tuner consists of the tuner and a collar bushing. The tuners are attached to the headstock with a
small wood screws.
1. There are two different types of tuners (item #9 on the
Material list): 3 that are mounted on the top of the Neck and
3 on the bottom of the Neck. When mounted correctly, the
adjustment knob should be closer to the end of the Neck
than the shaft;
2. Partially insert the shaft collar into the Neck hole (final
installation is covered in Section 4);
3. Insert the tuner, aligning the Tuner knob shaft to be
perpendicular to the Neck –mark hole locations and drill
starter holes with 1/16 drill bit –use caution when drilling
as the headstock is thin;
4. Repeat steps 2 & 3 for the remaining Tuners.
Carefully disassemble the Mockup and move on to the next step:
applying the finish to your guitar!
Figure 2.6.4 Tuner Alignment
CAUTION:
The headstock is thin –do not drill
through!!
Figure 2.6.3 Strap Pin Locations

Section 3 –Finishing Your Guitar
SG 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
SG 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
SG 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
SG 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
SG Section 4 - 1 -
4. Assembly..........................................................................................................................................- 1 -
4.1 Installing the Neck.....................................................................................................................- 2 -
4.1.1 Neck Positioning: Neck Cavity Insertion ...........................................................................- 2 -
4.1.2 Neck Positioning: Centering..............................................................................................- 3 -
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 Pickups....................................................................................................................- 5 -
4.2.3 Install Volume Controls.....................................................................................................- 5 -
4.2.4 Selector Switch Wiring and Installation (Reference Figure 4.2.4) ....................................- 6 -
4.3 Installation of the Bridge Components.....................................................................................- 7 -
4.3.1 Installing the Bridge ..........................................................................................................- 7 -
4.3.2 Installing the Tailpiece ......................................................................................................- 7 -
4.3.3 Install the Pickguard and Pickups......................................................................................- 7 -
4.4 Installing the Tuners & Truss Rod Cover (Figure 4.4)................................................................- 8 -
4.4.1 Installing the Tuners..........................................................................................................- 8 -
4.4.2 Installing the Truss Rod Cover...........................................................................................- 8 -
4.5 Install the Strings.......................................................................................................................- 8 -
4.6 Installing the Strap Pins.............................................................................................................- 9 -
4. Assembly
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
SG Section 4 - 2 -
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). Place painters
tape on the Body along the Neck pocket and then
locate the neck located “in and out” position -
mark the tape with a pencil so you can position it
correctly when it is glued and clamped.
Remove the Neck pickup.
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 SG Neck Centering

Section 4 –Assembly
SG Section 4 - 3 -
4.1.2 Neck Positioning: Centering
The neck needs to be aligned with the center of 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.
After protecting the finish on the Body, 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.

Section 4 –Assembly
SG Section 4- 4 -
4.2 Installation of the Electronic Components
After ensuring that the gluing process in previous section is completely dry, you can install the wiring
harness, volume & tone controls, selector switch, pickups, and output jack. The wiring harness, controls
and output jack come assembled reducing your task to making the final connections between the
selector switch & pickups. Wire strippers, solder, soldering iron and small needle nose pliers are
required for this section. Figure 4.2 illustrates the harness and configuration of other components, and
should be used for reference for this section.
4.2.1 Installing the Wiring Harness
As noted, the wiring harness comes assembled and only requires to be run through various tunnels prior
to being connected to other components using shielded wire. Figure 4.2.1-1 details the various Body
tunnels (...from a back view). Before starting the installation, inspect all of the harness connections to
ensure the integrity of the wiring.
Figure 4.2 SG Wiring Diagram, Reference