Guitarist Builds Guitar: Inlays

I was going to do something more elaborate with the inlays, but seeing that I have never done inlays I decided to use the Les Paul Custom inlays on this first guitar. I am not going to put a inlay at the 1st fret. Just to be different. Who knows you may end up seeing it used for a decorative inlay in the headstock.

First I have to screw the 5/16" aluminum plates to each side of the fret board.

As you see here

Then I position the inlay on the fret board and scribe a mark around it.

I then use chalk to highlight the mark. Then I used a straight edge and my miniature router with 1/8" down cut spiral bit to route out for the inlay. To make this a little easier. I figured out the distance from the edge of the router base to the edge of the bit. I then used my micrometer to position the straight edge. Then it was just a matter of holding the straight edge with one hand and turning on the and positing the router bit inside the scored area. Which was probably the hardest part. Especially on the last couple inlays which where very narrow. After using the router I have to square up the corners. I used an X-Acto knife for this which worked great. The first inlay took a while and I actually had to do it twice as the depth of the initial route was not deep enough.

1 down 8 to go.

I repeat the process.

2 down 7 to go.

All 9 inlays ready for epoxy.

I taped off the fret slots. Using 2 part epoxy then I glued the inlay in place.

I then mixed some saw dust I saved from the fret board when I sanded the fret board to size with the epoxy and filled the small gaps around the inlay.

1 down 8 to go.

Now I will wait until the epoxy cures and start filing and sanding the inlays.

Using a file I remove most of the excess inlay and epoxy. Cleaning the file often with a wire brush.

During the process.

Almost done with the filing.

I started with a 120 grit sandpaper on the radius block and then used 220 grit. I will go over it one more time with 320 grit prior to fretting. After using my 12" radius block I noticed one spot where I needed a little mote filler. Which was a very easy fix. Taped back over the close fret slot and added a little filler. Wait till dry and re-sand.