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One of the tasks in building a guitar that I truly despise is cutting fret slots in my fingerboards. So why don't I just buy serviced fretboards from LMI, etc.? Good question. I'm pretty hung up on building each of the components of my guitars by hand - so, I haven't gone there yet.

I've experimented with a process which seems to greatly accelerate the cutting of the slots. I'm wondering if there are any "gotchas" here that the more expereinced luthiers might have expereinced or anticipate.

I use the Stewmac jig and fretsaw, and perhaps the issue is the fretsaw has gotten a bit dull with use. Anyway, I find that my japanese pullsaw (with about a .018" kerf) cuts the slots like butter, and the jig keeps the saw at just about the right depth, when adjusted. Then I use the fret saw (.023") kerf for a smooth pass in the slightly narrower slot. Seems to go in without much trouble and the saw passes back and forth with a little resistance, but no chipping.

When gently pressing fretwire into the slot it feels snug, maybe a bit snugger than if I'd cut the slot with the .023" fretsaw. My only worry is that the slot may still be a bit narrower than .023" - and by touching up the slot with the .023" fretsaw, the fretboard may be "flexing" jsut a bit to accomodate the wider blade. Am I in process of inadvertently doing a "compression fret job"?

Thanks for your help.

I would lay the fingerboard on a flat surface and measure the slot with feeler gauges. Then you'lll know for sure.

Chuck

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You could always spring for the StewMac Japanese fret saw, though what you are doing should be fine.

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Fred Tellier
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Good idea, Chuck. Will do.

+1 on that.

A table saw sled is a breeze to use compared to any slotting jig out there.

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Alain Moisan
Former full time builder of Acoustics, Classicals and Flamencos.
(Now building just for fun!)

Providing your table saw doesn't have any wobble in it. Mine does and it shows up as a wide slot. Rather than fix the saw I'm considering going old school or buying the pre-slotted. I don't build enough to worry about the small extra cost of pre-slotted boards.

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Hutch

Get the heck off the couch and go build a guitar!!!!

Why not send or take your StewMac fret saw blade to Rockler and have them resharpen it. They do a great job on my table saw blades. I'm sure that they can keep the kerf width the same.

I had a Ryobi table saw, that only produced good cuts on a guitar width fretboard. Anything wider like a bass guitar and the slot curved on the end due to bad tracking of the skids in the tabletop.
I now have a Dewalt with accurate slides so my carriage remains straight and cuts true slots no matter the width. I put thumb stops on my carriage so my thumbs can't slide in front of the blade.

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Old growth, shmold growth!

Todd,

Yeah, I hear you. The truth is, I'm afraid of tablesaws... seems like the majority of folks who post "don't do what I did" injury shots did it with a table saw. I also don't really have room for one, so I'm not tempted. I recognize that a good setup on a table saw would solve the problem though.

Corky,
I did your exact method twice with success. My slotting jig had a clamp though, so the board was sure to be flat with the second saw. It is amazing how much faster the Japanese saw is, I will certainly consider the Stew mac version. Both guitars have the appropriate ability to have relief.

I can understand your resistance to a table saw, not that I would ever live without one, but you really don't have to have one for lutherie if you don't want to. Enjoy the peace of mind and quiet.
Rob

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Slot and fret a test board and have look. You will of course get a little backbow but if the slots are correct it should flatten out with moderate finger pressure. If you wanted to get anal about it you could slot a test board with each saw, fret them, and then cobble up a jig with kitchen scales threaded rod and a nut to measure the difference it takes to press them flat. I would not worry too much with that though cause over compression of the fb should be pretty obvious just by pushing down with ur finger.

Cheers

Kim

With the tablesaw system, how do you get the slots in exactly the right place? Do you buy a guide, or measure it yourself?

lol @ Filippo making his jigs with figured maple.

The man goes 100%.

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I read Emerson on the can. A foolish consistency is the hobgoblin of little minds...true...but a consistent reading of Emerson has its uses nevertheless.

StuMusic