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Some Carbon Fiber Action - new pics
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Author:  Stuart Gort [ Sun Apr 22, 2018 11:07 am ]
Post subject:  Some Carbon Fiber Action - new pics
This carbon fiber monocoque structure was formed inside of a wooden mold using unidirectional and braided sleeve formats. Once the resin cures the whole structure is a true hybrid carbon and wood block. CNC operations remove everything that ISN'T a neck. :)

This structure is continuous THROUGH the volute area and into the headstock.

There is no truss rod. Once you feel this neck for the first time, mounted on a body, you realize that a truss rod is moot. The rigidity is immense but it weighs only 2/3rds of the neck it replaced.

The hollow neck introduces an actual acoustic element into the electric neck. This greatly accentuates all harmonics. I was thinking it would when in the idea stage on this project...and it DOES. This neck went on a Strat body. All the Strat type noise are there...and are accentuated. It's quite musical.

The hollow cavity can be filled with a urethane based foam. The foam is easily adjusted to produce varying values of density. Therefore, the harmonic qualities can be controlled if desired.
Author:  meddlingfool [ Sun Apr 22, 2018 11:18 am ]
Post subject:  Re: Some Carbon Fiber Action
Pretty cool. You could also build a little trap,door and use it to store consumables. Like picks...
Author:  Stuart Gort [ Sun Apr 22, 2018 11:23 am ]
Post subject:  Re: Some Carbon Fiber Action
Ya huh...I could put dope in there.
Author:  rlrhett [ Mon Apr 23, 2018 4:50 pm ]
Post subject:  Re: Some Carbon Fiber Action
That’s probably not something I’d ever try, but I do work with CF. I always love knowing what can be done. What is the technique were seeing here? It looks pretty time and labor intensive.

Ps: haven’t you heard? You don’t need a secret compartment for dope anymore. It won’t be long before you can pick it up at a local store along with a fifth of Jack and a hard pack of Marlboro’s. Although the Marlboro’s are probably going to cost you five time as much as the dope, so maybe skip them.


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Author:  Stuart Gort [ Mon Apr 23, 2018 6:46 pm ]
Post subject:  Re: Some Carbon Fiber Action
rlrhett wrote:
What is the technique were seeing here? It looks pretty time and labor intensive.


A bladder is inflated inside the carbon sleeve to 100 psi.....expanding the material to the extremes of the wooden cavity. Once completely cured the block is machined until a neck pops out. I just push a button. :) Bladder molding is used extensively through aerospace, F1, cycling, and other markets where a monocoque structure is desired.

Yes...it's very time consuming but it DOES produce a very consistent result...I mean every time. This is one of the processes I used to make aircraft propellers...for that very reason.
Author:  rlrhett [ Mon Apr 23, 2018 7:03 pm ]
Post subject:  Re: Some Carbon Fiber Action
I assume you have to mill the cavity first to the exact size of the sleeve. So the neck is milled four times? Each half of the blank for the cavity, outside top, outside back? Glue up, holding jigs, vacuum infusion? As I said, looks like a lot of work.


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Author:  ernie [ Mon Apr 23, 2018 8:56 pm ]
Post subject:  Re: Some Carbon Fiber Action
very slick very high tech , very impressive . I like it!
Author:  Stuart Gort [ Mon Apr 23, 2018 10:33 pm ]
Post subject:  Re: Some Carbon Fiber Action
rlrhett wrote:
I assume you have to mill the cavity first to the exact size of the sleeve.


Not exactly. The braided sleeve is something like a Chinese finger torture...in that it WILL expand within a limited range.

rlrhett wrote:
So the neck is milled four times? Each half of the blank for the cavity, outside top, outside back?


Yes (that's very astute...btw), except the inside operations do not require any fine surfacing. That goes rather quickly.

rlrhett wrote:
Glue up, holding jigs, vacuum infusion? As I said, looks like a lot of work.


The programming and tooling is intensive. Beyond that it's about 8 hours of machine time and about 15 hours of hand work to complete a neck....ready to play.
Author:  rlrhett [ Mon Apr 23, 2018 10:35 pm ]
Post subject:  Some Carbon Fiber Action
Stunning, and beautiful, and very cool. Excellent work.

PS I’d love to see a picture of the whole completed neck.

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Author:  jfmckenna [ Tue Apr 24, 2018 10:21 am ]
Post subject:  Re: Some Carbon Fiber Action
Wow! That's really neat.
Author:  rlrhett [ Tue Apr 24, 2018 10:25 am ]
Post subject:  Re: Some Carbon Fiber Action
One more question: the carbon fiber layer looks to be 1/8” or more thick. But the weave of the sleeve can’t be more than 1/40”. What makes up all that thickness?


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Author:  Stuart Gort [ Tue Apr 24, 2018 5:46 pm ]
Post subject:  Re: Some Carbon Fiber Action
rlrhett wrote:
One more question: the carbon fiber layer looks to be 1/8” or more thick. But the weave of the sleeve can’t be more than 1/40”. What makes up all that thickness?


The sleeve is doubled...one inside of another. It takes a thin resin to wet out two layers together. Both layers together result in a wall thickness of .06". The rest of that thickness is due to an outer layer of unidirectional tows. You can pack that anywhere you want and make it as thick as you want....within limits.
Author:  rlrhett [ Tue Apr 24, 2018 6:40 pm ]
Post subject:  Re: Some Carbon Fiber Action
So what you are saying is that when you are done playing your Strat you can use it as a lever to prop up a bulldozer to change the tracks. [FACE SCREAMING IN FEAR]


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Author:  joe white [ Tue Apr 24, 2018 7:23 pm ]
Post subject:  Re: Some Carbon Fiber Action
That is not only cool but very impressive Stuart. I like it!
Author:  Stuart Gort [ Thu Apr 26, 2018 8:09 pm ]
Post subject:  Re: Some Carbon Fiber Action - more pics
rlrhett wrote:
PS I’d love to see a picture of the whole completed neck.
Author:  Durero [ Thu Apr 26, 2018 10:54 pm ]
Post subject:  Re: Some Carbon Fiber Action - new pics
Wow! That's very beautiful work Stuart!

Fascinating construction method and structure too.

How do you remove the bladder once the resin is cured? Does it come out the body end of the neck?

Very impressive :)
Author:  Stuart Gort [ Fri Apr 27, 2018 12:35 am ]
Post subject:  Re: Some Carbon Fiber Action - new pics
Durero wrote:
How do you remove the bladder once the resin is cured?


It stays inside...bound to the resin for eternity. :)
Author:  Chris Pile [ Fri Apr 27, 2018 5:44 am ]
Post subject:  Re: Some Carbon Fiber Action - new pics
Stuart - you never fail to intrigue me with your advanced thinking and techniques.
Author:  fingerstyle1978 [ Fri Apr 27, 2018 6:49 am ]
Post subject:  Re: Some Carbon Fiber Action - new pics
Curious how much weight this cuts out?
Author:  Clay S. [ Fri Apr 27, 2018 8:06 am ]
Post subject:  Re: Some Carbon Fiber Action - new pics
Stealth Carbon. Pretty Cool!
Author:  Stuart Gort [ Sat Apr 28, 2018 10:37 am ]
Post subject:  Re: Some Carbon Fiber Action - new pics
fingerstyle1978 wrote:
Curious how much weight this cuts out?


Without tuners it weighs a bit less than 2/3rds of the stock Fender neck. I like Sperzel (aluminum housings) tuners when weight is truly an issue.
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