I still used his wheatpaste recipe and the construction method is similar but follows a more traditional method of composite build-up, shaping the plies beforehand and laying up net as opposed to cutting the final shape out of a cured blank.
A disclaimer, of sorts: While this project is not a failure it does need some tweaking. Think of it as an advanced proof of concept. It looks great and I was able to get some sound out of it and show viability but a pretty daft design flaw in the headstock prevented full tension from being applied to the strings. I still show the whole process but at the end I'll point out the failures and discuss how I'm working to fix them. Hopefully I'll be able to strike this through soon when I apply a fix.
Step 1: Materials and Tools
- Corrugated Cardboard (Free) - It should be clean, unbent, and uncoated. Finding pieces large enough for the body is the biggest challenge. If you don't have any around, talk to someone at a store that sells appliances. One refrigerator box is probably enough for the entire project.
- Wheatpaste (Free) - A simple mixture of flour, water, and vinegar. 4-to-1 water to flour with a tablespoon of vinegar (as a preservative). Heat and stir until thickened.
- Machine Heads ($5 - eBay) - You need a total of 6 pegs, single or connected it doesn't matter.
- Bridge/Tailpiece ($8 - eBay) - Make sure you have both a bridge and a tailpiece. The bridge is what the strings pass over at the bottom of the body and the tailpiece holds the strings in place.
- 6 String Electric Pickup ($3 - eBay) - You can make your own with magnet wire and magnets, that was my original plan, but time constraints and the low cost of pre-built units.
- Strings ($2 - eBay) - The strings need to be for electric guitars or else the pickup will not work. Synthetic strings will not work.
- 2x 500k Potentiometers w/ Panel Nuts - For the pickup circuit, one controls volume the other helps control tone as part of a low pass filter.
- .022µF Capacitor - The other part of the tone adjustment.
- 1/4" Mono Audio Jack ($2 - RadioShack)
- 2x Set Screw Knobs
- Wood Glue
- Utility/Hobby Knife
- Soldering Equipment
- Wire Cutters
- Tuner - Or tuning forks, or another, tuned, instrument.
- Guitar Amplifier - Along with a M/M 1/4" cord.