o’brien neck joint routing jig · o’brien . neck joint routing jig. assembly instructions. it...

O’Brien Neck Joint Routing Jig

Assembly InstructionsIt is important that these instructions be followed carefully as assembling this jig out of sequence could prevent it from coming together correctly. These instructions rely mainly on drawings to illustrate the assembly, but in a few instances text containing helpful hints has been added. In addition to these written instructions, there is a video on our website demonstrating assembly and use of the jig. We hope your enjoy using your Neck Joint Routing Jig.

We recommend that brads and glue be used for assembly of this jig, but at a bare minimum glue if you don’t have access to a brad gun.

Hardware included: 2 - 5/16”-18 all thread 7” long2 - 5/16”-18 threaded knobs7 - 5/16” flat washers (used in two locations)2 - 5/16”-18 hex locknuts2 - 5/16”-18 tee nuts4 - 1/4”-20 x 3” carriage bolts4 - 1/4” flat washers4 - 1/4”-20 hex nuts4 - 1/4”-20 knobs (vibration absorbing)6 - #6 wood screws (6 already installed)1 - 5/16”-18 x 4-1/2” carriage bolt3 - 5/16”-18 hex nuts2 - 1/4”-20 x 1” knob w/stud2 - 1/4”-20 tee nuts1 - 21 1/2” slotted aluminum angle extrusion2 - 10-32 x 3/8” threaded inserts2 - 10-32 x 5/8” machine screws4 - 1/4”-20 x 3/4” socket head screws (packaged with template) 4 - 1/4”-20 tee nuts (packaged with template)1 - 1/8” Allen wrench (packaged with template)1 - 9” x 12” x 1/16” cork (cut up for padding, see instructions)2 - 1/4” plastic dowel pins (for neck alignment w/truss rod slot)

Recommended Tools:Hammer1/2” combination wrench7/16” combination wrenchElectric drill

1. Base Plate 2. Base Right Side

3. Base Center 4. Base Left Side

I. Base Assembly

5. Insert Carriage Bolt 6. Add Washer

7. Add Nut

I. Base Assembly - cont.

1 - 5/16”-18 x 4-1/2” carriage bolt 1 - 5/16” flat washer

1 - 5/16”-18 hex nut

Router bits for routing both straight or dovetail mortise and tenon components are available at http://www.lmii.com/products/tools-services/rout/shape/drill/neck-joint-jig-and-templates

1. Install Tee nuts 2. Attach Brace

3. Brace Assembled

II. Body Clamp Plate Assembly

4. Affix Cork

2 - 5/16”-18 tee nuts

1. Threaded Rod 2. Locknuts

3. Washers 4. Front Plate

III. Body Clamp Assembly

2 - 5/16”-18 allthread 7” long 2 - 5/16”-18 hex locknuts The locknuts are very difficult to thread on if you at-tempt to do it by hand. We recommend chucking the all thread up in your drill and using a box wrench to thread them on to approximately two inches from the opposite end where you began the threading. See inset photo.

2 - 5/16” flat washers

Thread nut to here.

5. Cork 6. Washers

7. Knobs

III. Body Clamp Assembly - cont.

9” x 12” x 1/16” cork 2 - 5/16” flat washers

2 - 5/16”-18 threaded knobs

Permanently attach the knobs with a threadlock compound (Loctite, etc).

The cork should terminate 1/8”+ from the notched edge of the Body Clamp Assembly so it fits into the Top dado later in the assembly.

1. Tee Nuts/Carriage Bolts 2. Tee Nuts/Carriage Bolts Installed

3. Washers 4. Nuts

IV. Neck Pivot Plate Assembly

2 - 1/4”-20 tee nuts 4 - 1/4”-20 x 3” carriage bolts

4 - 1/4” flat washers 4 - 1/4”-20 hex nuts

1. Marked Hinge Location 2. Hinge Aligned and Attached

V. Neck Pivot Plate Mounting

We recommend you pre-drill the two outside holes with a 3/32” drill bit. Install the two outside screws snugly, but not fully tightened. There is enough play in the hinge holes to allow for small adjustments. Adjust the hinge to align with the pencil markings then install the remaining 4 screws and tighten all.

6 - #6 wood screws

1. Tee Nuts 2. Tee Nuts Installed

3. Body Clamp 4. Body Clamp Plate

VI. Top Assembly

4 - 1/4”-20 tee nuts (packaged with template)

5. Right Side 6. Left Side

7. Templates Attached 8. Right Riser Attached

VI. Top Assembly - cont.

See explanatory text next page. (squared to edges)

9. Left Riser Attached

VI. Top Assembly - cont.

Install the 1/4” -20 x 3/4” socket head screws through the template slots into the threaded tee nuts under the templates. Be sure you have the templates on the correct side of the jig as shown in the drawing. Square each template (mortise and tenon) to the front of the jig. When the templates are square, tighten the socket head screws. Now dry fit the left and right risers. There should be a very small gap between the risers and the templates. Too small a gap and the templates won’t slide properly, too wide and they’ll be slop-py. We recommend putting a small shim between the riser and the template such as a piece of paper or blue painters tape to act as a shim. Once you are comfortable with the dry fit, apply wood glue to the risers and place them back on the jig. The risers can be taped down as one would do with binding on a guitar and weighted in the center or clamped until dry.

Check out LMI’s great selection of neck blanks atwww.lmii.com/prod-ucts/mostly-wood/neck-woods/neck-blanks

1. Overview UnassembledDecision Time

2. Overview Assembled 3. Close up of pocket

VII. Final Assembly

At this point you need to decide whether you will make the final assembly permanent or if you would prefer to be able to disassemble these two sections when not in use. If perma-nent - glue and clamp, if temporary, you can hold the sections with through bolts and nuts, (not included).

http://www.lmii.com/prod-ucts/mostly-wood/neck-woods/neck-blanks

6. Neck Clamp View

VII. Final Assembly - cont. 4. Base Left Side Installed Close up 5. Nuts and Washers

2 - 5/16”-18 hex nuts 2 - 5/16” flat washers

7. Neck Clamp Plates Install cork on neck plates as shown in photo inset before using.

The 5/16” carriage bold shown needs hardware attached. Swing the neck clamp out so that the carriage bolt can be accessed. Install 1 5/16” nut, then 1 5/16” washer then replace the neck clamp and in front of it add another 5/16” washer and another 5/16” nut. This is the way you will lock your neck angle once you have determined it.

9. Angle Extrusion

10. Angle Extrusion Knobs

VII. Final Assembly - cont.

1 - 21 1/2” aluminum angle extrusion

2 - 1/4”-20 x 1” knob w/stud

4 - 1/4”-20 knobs (vibration absorbing)

8. Neck Clamp Knobs

www.LMII.com for all your

lutherie needs!

1. Centerline Overview 2. Centerline Closeup

3. Centerline Inserts

VIII. Centerline Installation

2 - 10-32 x 3/8” threaded inserts

4. Centerline Inserts Installed

The center line acrylic extends beyond the bottom edge of the jig for a long sight line when centering the guitar. It is meant to be removed from the jig after the body align-ment is complete, both to allow you to rotate the jig and for storage purposes.

2 -10-32 x 5/8” machine screws

5. Centerline Screws

8. Neck Side View7. Body Side View

VIII. Centerline Installation - cont.6. Centerline Screws Installed

o’brien neck joint routing jig · o’brien . neck joint routing jig. assembly instructions. it...

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