!www.chillenguitars.com! Kit Assembly Assembling a Chillen Cigar Box guitar kit! Parts included with the kit - Wooden Cigar Box! - Neck with pre-drilled headstock! - Blank finger board with routed slot for nut! - 4 machine tuners (2 left, 2 right)! - bolt for nut! - bolt for bridge! - angled metal, drilled string anchor with 4 self tapping screws! - 4 steel guitar strings (.036, .026, .017, .013)! - Pre-soldered Piezo pickup with output jack! - 4 #6 1-1/4” flat head wood screws! - 4 #6 3/4” Phillips Pan self-drilling screws! - 1”x2” wood for bracing ! Tools Needed to assemble kit (note: This kit can be assembled using hand tools, instructions will consider using hand tools. Simple power tools, if available, can be used) 1. Handsaw- preferably a coping saw or Japan saw! 2. Utility knife! 3. Wood file! 4. Tape measure! 5. Straight edge ruler ! 6. Wood glue! page "1 !www.chillenguitars.com! Kit Assembly 7. Phillips head screw driver (medium and small bit)! 8. Drill with 1/16” and 3/8” drill bits! 9. Wood finish of your choice (Tung oil, Stain, polyurethane, varnish)! 10. Sand paper 220grit, 400, 600 (optional)! - ! - NOTE: This guitar can be built in about 1-2 hours minus time needed to allow glue and neck finish to dry. Read ahead in the instructions and make sure you understand each step before moving on. A wise man once said “measure twice, cut once.” ! - FOLLOW ALL RECOMMENDED SAFETY PRECAUTIONS WHEN WORKING WITH WOOD AND SHARP TOOLS. ALWAYS WEAR EYE PROTECTION, AND SKIN AND BREATHING PROTECTION WHEN WORKING WITH FINISHING CHEMICALS.! - The beauty of DIY cigar box guitars are the many variations that can be applied. Number of strings, scale length, drilled sound holes, Fret or no fret are some of the options available. Plan ahead and consider the modifications/improvements/additions before you begin the project. ! - This kit was created to be easily assembled without power tools. The guitar created will be fretless 4-string with string action that will accommodate “Slide” playing. ! page "2 !www.chillenguitars.com! Kit Assembly - The scale length is not exact and can be modified as the user wants. The neck length will work for scale lengths between 24” and 26”. For general purposes I’ve included a sheet with markings for 24 3/4” scale guitar. ! - You have the option to add frets. Fretting will not be covered in this instruction manual.! - For additional information check our website: www.chillenguitars.com! Fitting the neck to the Box 1. Determine which end of the box will have the neck enter. ! 2. Use measuring tape or ruler and measure to the center of the box. This will be the centerline of the neck. Mark the center point on BOTH ends of the box! 3. Using the centerline mark measure 3/4” in either direction and mark on the edge of the box. This is the width of the neck and will be the side edge where you will cut.! 4. Using your straight edge measure down 3/4” on the box at either mark. Since the neck will sit below the lid, add the thickness of the lid to that measurement (For most boxes it will be around 1/4”). ! 5. Using your straight edge,carefully draw a horizontal line connecting the the 2 vertical lines. This is the area that will be removed to insert the neck. ! 6. Tip: Use masking tape to mark off area to be removed! 7. Using your saw and file cut away that area BE CAREFUL NOT TO CUT TOO MUCH away. Use your neck to check your work.! page "3 !www.chillenguitars.com! Kit Assembly 8. Once the neck slot is cut, measure the height from the base of the box to the bottom of the slot and cut a piece of 1x2 that height. Use a miter box or carpenter’s straight edge to make this cut square! ! 9. Cut an additional 1x2 the same height for the other end of the box. These 1x2 pieces will be the the attachment points for the neck. ! 10. With the 1x2 in place, place the neck in the slot and check the fitting. The neck should be snug in the slot and the box lid should be able to close. ! 11. When you have proper fitting, glue and clamp the 1x2’s in place and set aside to dry.! ! Fingerboard and neck construction - The next step is the prepare the finger board to be installed on the neck. The finger board is shipped with a routed slot at one end that can be used as the “nut” with the enclosed 1 1/2 bolt. If you choose to use a different type of nut you can always cut off the slot and use the remaining length for what you need.! - The most important measurement is scale length. Scale length determines fret locations. With a fretless guitar fret location (even without the actual frets) determines the correct note. With correct fret locations, dependent on scale length, the note page "4 !www.chillenguitars.com! Kit Assembly sounded at the nut (for example and “E” note) will be the same at the 12th fret (also an “E” just 1 octave higher). ! - Scale length is measured from the nut to the bridge. A guitar that has a 24 3/4” scale length, the nut and bridge are 24 3/4” apart. The fret positions are calculated so the notes in the chromatic scale are accurate on the instrument. ! - We’ve included a template guide for 24 3/4” inch scale guitars. This template will allow you to mark the fret positions on the finger board. Depending on the size of the box you can have anywhere from 18-22 fret spots. ! - These marks can be done in pencil and the user has the option to cut slots and add frets. It’s up to the builder to decide that. The guitar will still be playable without frets.! - Once the fingerboard is laid out, it will be trimmed and glued to the top of the neck.! 1. Place the paper with fret marks so that the nut marking on the paper lines up with the center of the routed nut slot on the fingerboard.! 2. With a pencil, place a tick mark at each fret marking corresponding with each fret number.! 3. Use a straight edge with a square to mark fret marking across the fingerboard.! 4. To make fret slots, use a coping saw and cut into the wood about 1/16”.! ! ! ! page "5 !www.chillenguitars.com! Kit Assembly Measuring and cutting the neck and fingerboard - The neck is cut from a 30 inch length of 1x2. It needs to be cut to fit in the box at the correct length.! 1. Place the fingerboard on the neck so the nut slot is located where the headstock angles away from the neck. That is the nut position. Mark the position of the nut on the neck.! 2. From that nut position measure 24 3/4” down the neck and place another mark. That is the bridge position.! 3. The bridge position should be about 1 1/4” to 1 1/2” inches from the back of the box. ! 4. Align the neck so the bridge marking is approximately 1 1/4” - 1 1/2’ from the back of the box. Make a mark so the end of the neck will butt against the back of the box. Cut off excess length. VERY IMPORTANT TO DOUBLE CHECK THIS MEASUREMENT BEFORE CUTTING!!!!! page "6 !www.chillenguitars.com! Kit Assembly Installing the fingerboard 1. The neck should sit inside the box with the end butted to the back of the box and the lid should be able to close.! 2. Place the finger board on the top of the neck with the nut slot aligned with the nut marking on the neck. ! 3. Mark the fingerboard at the INSIDE edge of the cut slot of the box. This is where you will cut excess from the fingerboard.! 4. Cut the excess using a miter cut. The finger board should butt to the closed lid of the box.! 5. Glue the fingerboard to the neck being careful to align the nut slot to the neck mark and keeping the sides flush. Clamp in place and let glue dry.! page "7 !www.chillenguitars.com! Kit Assembly ! Shaping and finishing neck - Once the fingerboard is glued on and dried, you can shape the neck using a file or sandpaper. This is another optional step. Some people like their necks rounded others like them square. ! - What is important is that you DO NOT shape the neck past the point where it enters the box.! - After you have shaped the neck you are ready for finishing. This could be staining and varnishing. How you finish the neck is up to you. I’ve used stain with a polyurethane built in. Tung oil without any stain. Spray on Varnish. Use the technique you feel comfortable doing. Remember this is your guitar, make it your own.! - It’s best to have the neck finished before the final install onto the box.! Installing the completed neck onto the box - Now that your neck is finished it is time to install it in the box. All the hard work of measuring is complete. now we just need to drill the holes and screw the neck into the box. ! 1. Have a carpenter’s square standing by. It is important that the neck be square to the box when it is installed.! 2. Test fit the neck into the box.