BYO Guitar JEM, Assembly

Page 1: ...JEM Guitar Kit Assembly www byoguitar com ...

Page 2: ...ses you wear meet the appropriate standards of the American National Standards Institute ANSI Because there are various ways to cut and join wood you can make substitutions for the methods stated in this manual We try to suggest the easiest methods possible However only you know your skills with each piece of machinery Never compromise your safety by using a cutting method with which you are not c...

Page 3: ...3 2 5 Fit check of the Tremolo Jack Fig 2 5 1 and Truss Rod Adjustment Cover 3 2 5 1 Tremolo cover 3 2 5 2 Output Jack Cover 3 2 5 3 Truss Rod cover 3 2 6 Check Strap Pins 3 2 7 Check Tuner Alignment 4 2 8 String Retainer Bar 4 2 9 Mockup and Fit Check complete 4 3 Finish 1 3 1 Finish Application Steps 2 3 1 1 Solid Color finish 2 3 1 2 Pigmented Translucent Gel stain or alcohol dye finish 2 3 1 3...

Page 4: ...ng Retainer Truss Bar Access Cover 6 4 8 1 Truss Access Cover 6 4 8 2 String Restraint 6 5 Initial setup 1 5 1 Adjust the Guitar Neck Truss Rod 2 5 1 1 Check the Neck 2 5 1 2 Adjusting the Truss Rod 2 5 2 String Lubrication 2 5 3 Re check the Bridge Alignment 3 5 4 Adjusting the Action string height 3 5 5 Pickup Height Figure 5 4 4 5 6 Intonation Figure 5 6 4 5 7 String Retainer Adjustment 5 5 8 O...

Page 5: ...ishing materials especially if they have to be ordered will allow expedite your guitar project We carry a full line of finishing products to give you the beautiful finish you are looking for whether a clear natural finish or a bold colorful finish We also carry an instructional DVD made by Behlen that will give you step by step instructions to help you achieve the look you want for your custom gui...

Page 6: ...rent tuners ensure that these parts are accounted for Please contact BYOGuitar if there are any discrepancies JEM Material List Item Component Quantity Description 1 1 JEM Body 1 JEM Neck Miscellaneous materials see below BYO JEM Guitar Kit 2 1 JEM Pickguard with pickups 3 18 screws 3 8 spare Mounting screws for Pickguard Audio Jack Back Plate 4 1 2 mounting inserts screws JEM Bridge Tremblock TIP...

Page 7: ... Wammy bar 7 4 ferrules 4 screws 13 4 Neck mounting materials 8 6 Tuning Pegs 6 Washers 6 Nuts 6 screws 3 8 Tuning Peg materials 9 Jack Back access cover Output Jack 10 2 Holders 2 plastic washers 2 screws 1 Strap Holder materials 11 1 retainer 2 screws String retainer materials ...

Page 8: ...rod cover 15 Output Cable 3 Allen wrenches Other 1 2 Additional tools materials required Drill drill bits 1 2 Phillips screwdriver Soldering iron solder Masking painters tape Finishing painting material Sand paper 220 320 grit Guitar strap Soap or candle Feeler gauge ruler Wood glue Wire cutter ...

Page 9: ...the finish has been applied and completely dried In this section all of the components are installed internal wiring connected and strings attached your guitar will ready to go Section 5 Setup in this section adjustments are made to your guitar such as the height of the pickups Again we thank you for your purchase of a BYO Guitar and we look forward to seeing pictures of your unique guitar We also...

Page 10: ... Rod cover 3 2 6 Check Strap Pins 3 2 7 Check Tuner Alignment 4 2 8 String Retainer Bar 4 2 9 Mockup and Fit Check complete 4 2 Mockup and Fit Check The following steps will ensure that the base neck tuners pickups etc are properly aligned and that all screw holes have been drilled 2 1 Checking the Mounting Holes in the Neck 1 Check the neck for pre drilled 4 mounting holes 2 Skip to 2 1 2 if the ...

Page 11: ...with 4 7 x 1 3 8 screws and ferrules item 7 on material list but do not over tighten them 2 2 The Bridge Mounting the Bridge assembly item 4 on material list on the JEM guitar utilizes two inserts in the Bridge Pocket Fig 2 1 that will be installed in Section 4 When finishing the Body Section 3 be careful not to allow finish material into the insert holes 2 3 Fit check Alignment of the Pick Guard ...

Page 12: ...mbly process easier pre tin the claw ground point raised tab in the center of the claw 2 Using the claw as a template mark the hole positions and pre drill 2 holes 3 Start the mounting screws approximately into the Body ensure they are centered Figure 2 4 2 5 Fit check of the Tremolo Jack Fig 2 5 1 and Truss Rod Adjustment Cover 2 5 1 Tremolo cover 1 Place cover over Tremolo pocket pearl finish up...

Page 13: ...crews 1 Insert tuners 6 each item 8 on Material List into the Neck Headstock Ensure that the Tuner shafts are perpendicular to the Headstock Fig 2 7 2 Check alignment of set screw holes and tuner base 3 If alignment is incorrect or holes are not drilled mark hole locations and drill starter holes with 1 16 drill bit being careful not to drill through the headstock 2 8 String Retainer Bar The two 2...

Page 14: ...trating stain or water based dye The guitar body was sanded at the factory and coated with one coat of sand and sealer To get a good finish the body should be sanded with a series of sandpaper grits up to 320 grit Apply a solid color finish a pigmented translucent finish Bursts toners Blonde Butterscotch Blonde etc a gel based stain or an alcohol based dye finish over the sanding sealer If you pla...

Page 15: ...ter based dye finish 1 Sand the body and neck to bare wood 2 Apply grain filler if desired 3 Apply stain or dye 4 Apply 2 coats of sand and sealer 5 Sand to 320 grit 6 Apply clear top coats 7 Buff finish 3 2 Explanation of Sequence Steps 3 2 1 Sanding the Body and Neck 1 Wear a NIOSH approved respirator and ANSI approved safety glasses when sanding wood 2 Before starting the finish on the neck mas...

Page 16: ...filler The dyes used in darker fillers may over time find their way through the color coat Apply the filler by wiping across the grain You can use a course cloth or your fingers to wipe the grain in After it has dried about ten to twenty minutes the excess can be removed with a cloth dampened with mineral sprits After about an hour repeat the process and let dry overnight If you have removed most ...

Page 17: ... have been applied DO NOT sand through the finish be careful on the edges Use a tack cloth to remove sanding residue Apply more finish sanding between coats until the finish is the desired thickness 3 2 7 Buff finish When the final coat has dried at least a week preferably a month remove the masking Wet sand the finish using 600 grit wet dry sandpaper with a sanding block followed with 1000 grit w...

Page 18: ... and thoroughly dried we can now assemble your guitar In this section we will permanently install all of the components and solder the wiring for the bridge and pick guard pickup 4 1 Installing the tuners Each tuner consists of the tuner washer and a threaded bushing The tuners are attached to the headstock with 3 8 wood screws refer to Section 2 7 1 Place the six tuners into the holes on the back...

Page 19: ...ck cover pearled surface up 4 3 Installing the Strap Pins Secure each strap pins 2 in the pre drilled holes with the supplied screws 2ea 1 4 4 Assemble Pick Guard Bridge and Neck to Body Refer to Figure 4 4 during this section Noted wiring colors are typical and may vary 4 4 1 Pick Guard Controls Installation 1 Check the wiring harness and the integrity of the solder joints referring to Figure 4 4...

Page 20: ...g through the tunnel Figure 4 4 1 2 between the Control Pocket and the Tremolo Pocket in the back of the Body c Seat the Pick Guard gently pulling the wires to ensure they are through the tunnels d As done in the Mock up Section 2 3 carefully move the Pick Guard so that it is aligned with the Neck Pocket and the contours of the body Using 3 8 screws item 3 on Material list attach the Pick Guard 4 ...

Page 21: ...uring it is centered in the Pocket so that about of the screw threads are exposed This allows you to adjust the tension of the springs 3 Insert the adjustment screws into the inserts final height adjustment will be made when the strings are installed 4 Solder the bridge ground wire to the tab on the trem claw 5 Prior to installing the trem block set the Fine Adjustment screws to mid range Fig 4 4 ...

Page 22: ...n the tuners so that the hole is parallel to the tuner shaft 2 While holding the bridge assembly by the string locking bolts use the 3mm Allen wrench to adjust the initial height of the bridge base so that it is approximately 1 8 above the Body Ensure that the base notches are in the collared head of the adjustment screw Fig 4 5 1 3 Carefully uncoil each of the strings 6 ensuring that the stings d...

Page 23: ...peat 1 2 on remaining strings 4 Recheck tuning on all strings repeat 1 2 3 as necessary 5 Install the Tremolo cover over the Tremolo pocket using supplied 3 8 screws 4 7 Installing the Strap Pins Secure each strap pins 2 in the pre drilled holes with the supplied screws 2ea 1 4 8 Installing the String Retainer Truss Bar Access Cover 4 8 1 Truss Access Cover 1 Place the pearled access cover item 14...

Page 24: ...e preliminary settings from which you can fine tune the sounds to your individual playing style As with previous sections references are included for visualization and additional clarification of specific adjustments reference check out the following references that can be helpful in tuning your guitar tone generator for tuning http www get tuned com online_guitar_tuner php http www guitarforbegin...

Page 25: ... the neck to warp backward too much and the strings will buzz on the frets and loosening it will cause it to bow forward giving more relief CAUTION If you find that the truss rod is very difficult to turn then stop It may be that there is a problem with the neck or the truss rod and you may damage the guitar by forcing it Sight down the edge of the fingerboard from behind the headstock looking tow...

Page 26: ...ht of the strings over the 12th fret Minor adjustments are made by raising or lowering the bridge which was previously set to 1 8 above the Body As this is a matter of personal preference this initial adjustment will give a place to start There should be a gradual increase in height from the first string to the sixth string Adjusting saddle height is very easy on the JEM guitar Since the bridge ca...

Page 27: ...machinist ruler measure the distance from the top of the pole to the bottom of the 1st string note bass measurement 1 3 Repeat 1 1 1 2 on the 6th string note the treble measurement 2 Center Pickup repeat steps 1 1 through 1 3 above on the center pickup noting measured heights 3 Neck Pickup repeat steps 1 1 through 1 3 above on the neck pickup noting measured heights Using Table 5 4 as a reference ...

Page 28: ...ht downward angle from the nut to the tuners Ensure nut locking bolts are secure 2 Check that all pocket access covers have been screwed down pearled side out and that protective material has been removed 5 8 Other Hints There are a few other things that you can do to optimize your tuning stability 1 Each time you play your guitar before you do your final tuning play for a few minutes to allow the...