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Bolt-on techniques without the aid of a Router

As much as I'd like to learn to how to route a neck pocket to do a bolt-on neck, I don't have a router, and it looks like I won't be buying one for quite some time. I'd still like to do bolt-ons, though, and I've been looking over the archvies at the forum to see how others have MacGuyvered their own without a router.

This crudely-drawn picture describes the 2 techniques I've come across here at CBN and at various places around the interwebs. In both cases, a wood rail is glued either directly to the neck, or on the opposite side of the cigar box wall. A bolt can then be plunged through the rail, ending in the neck:

The top drawing has been modified by a few people so that the rail runs parallel underneath the neck, not perpendicular, across the length of the box.

I bring this up because I want to open things up for discussion: additional examples, comments, criticisms of the technique, etc. Please feel free to comment, especially if you've tried any of these techniques.

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Permalink Reply by ChickenboneJohn on October 2, 2010 at 5:07am

Here's how I do it. You need plenty of overlap on the joint and a minimum of two decent screw fixings.

In your sketches , if the screws held the string tension would tend to rotate the neck the block and try and distort the box or pull it apart. The screws are shown way too short, and the second sketch has a fixing into end grain -it would pull straight out.

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Permalink Reply by ChickenboneJohn on October 2, 2010 at 5:09am

Here's my sketch.

Attachments:

neckjoint.jpg, 25 KB

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Permalink Reply by Mister Scott on October 2, 2010 at 6:15am

ChickenboneJohn said:

In your sketches , if the screws held the string tension would tend to rotate the neck the block and try and distort the box or pull it apart. The screws are shown way too short, and the second sketch has a fixing into end grain -it would pull straight out.

Sorry, instead of "crudely drawn", I guess I should have written "incredibly rough".

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Permalink Reply by c# merle on October 2, 2010 at 6:58am

this is exactly how i do mine. never had any problems with the neck using it

ChickenboneJohn said:

Here's my sketch.

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Permalink Reply by Mister Scott on October 2, 2010 at 7:00am

Good to know. Thanks everyone!

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Permalink Reply by Skeesix on October 2, 2010 at 7:22am

I've done it like version #2. On a 21" scale it was fine, but on a 24-3/4" scale it was a bit wobbly. There wasn't enough room to put in 2 screws like I wanted to. But it's still holding after several years.

I think Chickenbone's version is a wonderful solution.

For my version, I notched the block on the bandsaw, then glued another piece across of the back of it to form a pocket. Then I glued the whole assembly into the box.

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Permalink Reply by Mister Scott on October 2, 2010 at 7:31am

Skeesix said:

For my version, I notched the block on the bandsaw, then glued another piece across of the back of it to form a pocket. Then I glued the whole assembly into the box.

Hey Skeesix, thanks for the input. My slow brain is having trouble visualizing it, though. Can you post a rough sketch?

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Permalink Reply by Mark Werner on October 2, 2010 at 9:31am

I have built several, including an 8-string full-tension mandola, using a technique very similar to your second illustration.

Rather than running a screw in, however (difficult to do this inside the box) I use either "screw-bolts" (half threaded as a wood screw, half threaded as a bolt, no head) or a "furniture insert".
Both work well; I used the furniture insert on the mandola and have been playing it for about a year now with no sign of any problem.
Naturally, the inside of the box on that end needs to be reinforced, but I have been using a simple piece of 1/4" oak glued to the side... Seems to work fine.

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Permalink Reply by HOGS GRUNT on October 2, 2010 at 8:19pm

This is the way I do it. The two side 'cheeks' are to stop the neck from pulling sideways and helps to support the neck. No router just a saw and chisel.
Hope this helps.C:\Documents and Settings\0\My Documents\My Pictures\Del\the-ol-99er-19.htm

C:\Documents and Settings\0\My Documents\My Pictures\Del\the-ol-99er-19.htm

Hogs.

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Permalink Reply by Mister Scott on October 3, 2010 at 2:45am

HOGS GRUNT said:

This is the way I do it. The two side 'cheeks' are to stop the neck from pulling sideways and helps to support the neck. No router just a saw and chisel.

Hey Hogs, seems your upload didnt work...

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Permalink Reply by Dan Sleep on October 3, 2010 at 3:51am

He accidentally posted a link to the data on his local hard drive.

Scotty C. said:

HOGS GRUNT said:
This is the way I do it. The two side 'cheeks' are to stop the neck from pulling sideways and helps to support the neck. No router just a saw and chisel.

Hey Hogs, seems your upload didnt work...

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Permalink Reply by Dan Sleep on October 3, 2010 at 4:16am

LOL

Naz Nomad said:

Iggy said:
He accidentally posted a link to the data on his local hard drive.

Luckily it wasn't from his C:\Documents and Settings\0\My Documents\My Pictures\Del\naked-at the-computer folder. :-))