I recently repaired a guitar for a co-worker. The neck had been broken. The old neck was removed from the fret board using a saw from TFWW. Some “mahogany” was obtained and squared up using handplanes. The old neck was then used as a template for the new neck but the neck was made thicker to fit the owners hands better. The groove for the truss bar was made using a handsaw followed by a hand router. The new neck was then rough cut out using a bandsaw.After shaping the neck with rasps and sandpaper, the end where the tuning knobs go had to be done. This was accomplished by first flattening the top side with a handplane and then clamping it down onto the bench with two matching height boards. A hand router was then used to flatten the back and ensure it was parallel with the front. The holes for the tuning knobs were then done. The truss bar was installed and the new neck was epoxied to the fret board and guitar body. After curing, the neck was given a final sanding and strings fitted. Some frets required leveling, but the guitar is fixed to his liking. It sounds real good and fits his monster hands. He will take care of refinishing the neck.
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