Sanding and Pore Filling

Sorry no photos of the exciting task of sanding, but pretty standard, 80 grit with a orbital sander, 80 grit by hand then 150 grit by hand then 220 grit by hand..

After sanding it is on to pore filling, there are as many methods of pore filling as there are luthiers, I'll be using two methods for this guitar. For the back and sides I'll be using Zpoxy brand epoxy. I've used it before and it works well under a French polish. For the neck I'll just be wet sanding with shellac.

The Zpoxy needs to dry overnight then get sanded (more sanding) then probably a second coat and more sanding to insure all the little pores are filled.

Nice thing about Zpoxy is you start to get and idea of what the finished guitar will look like

Back & Sides  First pore filling

Looks good

High tech applicator....

Cutting Shell and Inlaying

I've done one simple inlay before, since this is what I call a Celtic tenor guitar should have a Celtic inlay.. So gave that a try.. The inlay will go on the peghead.. I tried a couple of methods to cut the shell but in the end went with the tried and true jeweler's saw and needle files..

I considered trying to leave some wood in the voids between the arms of the design when I routed out the opening but decided they were so small it would be impossible. So I routed out the entire shape and glued in the shell with 5 minute epoxy coloured liberally with lamp black.. Left everything a little high then sanded smooth..

All in all I think it worked out good!

V block & Jeweler's saw with the cut out design

Just sitting on top of the neck

the pocket for the shell routed

glued in and filled with epoxy and lamp black

sanded smooth