How to cut a string nut?

[MWaldorf]

OK, I'm working on my V3 project, and this one has me a bit puzzled. I've got a string guide/nut thing that's already been notched, but it's a full cylinder. Obviously I need to cut it to size. Judging from my '66, I need somewhat less than half. So, this cylinder I've got is brass. What's the best way to cut this in half? Once it's in half I figure I'll use hand files to shape it. My guess on cutting in half right now is a dremel, but is there some other tool I should use?

Thanks!

[dubtrub]

First of all you'll need to determine how much metal to take off to make the flat side fit properly. If you take off too much and the string guide sits too low obviously you'll have a problem with the strings slipping out of the slotted guide. Next you don't want it to be to high as the string will be lifted above and off the zero fret.

There are a multiple ways to cut the flat sides. Probably use what ever works best for you. My preferred method is to clamp it standing vertically in a vise with the jaws leather padded, then use a hack saw and cut along the length down to the vise jaws. Then flip it around and saw from the other end to meet the area you just cut. leave plenty of material so that it can be hand filed down to the final height or depth in accordance to the zero fret. I use a thin metal ruler that I lay across the zero fret into the fret guide slots to determine the correct amount that needs dressing off the bottom. You want the string to rest 'on' the zero fret with the slots in the guide used only as a guide, not as a nut.

Or......You can use a bench grinder to ground away one side to make it flat. Grinding gets hot real fast so you have clamp it with something to hold it while grinder. Keep a can of water close by to continue quenching it as it gets hot. Or......you can clamp it in a vise and file till your hearts content, or worn out.

Also, depending on which method you choose to mount it, you may have to make a flat side on the back of the guide where it meets up against the fretboard. I have seen these guides mounted two ways. One, flat side against the fretboard, the other, an angled notch cut all the way across the edge of the fret board so that the rounded edge of the guide fits back into it. This is obviously a lot more work as Semie dropped this method in '64. But it does make for a clean looking installation.

When it's ready to be permanently installed after painting, use a little bit of glue to secure it in place or else it will never stay in tune.

[MWaldorf]

Thanks Danny. I'll probably give the vice & hacksaw route a try. Hack that I am, I'm familiar with a hacksaw

The guide on my '66 has the guide filed to have the guide edge flush with the fretboard. It does look nice, but I'll have to see how much space is alloted for the guide on the neck I get, as the last neck was cut for a full semi-circle.

As an aside, I've never seen a brass string guide before, I've only seen the aluminum ones. (? they're silvery, I'm guessing they aluminum) Strange things at the bottom of the Moseley parts bin.

[dubtrub]

As an aside, I've never seen a brass string guide before, I've only seen the aluminum ones. (? they're silvery, I'm guessing they aluminum) Strange things at the bottom of the Moseley parts bin.

From 1964 on they were all nickel plated brass. At least on all the ones I've seen or worked on. Just like tuning key heads, they tarnished and become dull appearing to be aluminum. The very early Mosrites, back when Semie was hand making a lot of parts had aluminum string guides.

[dubtrub]

Mel, while searching the various site I came across this photo that depicts what I was trying to describe in my above post about the string guide. Although it is painted wood and more than a little exaggerated, it does give a clear view of how the zero fret is actually the nut that the strings ride on and the guide is just there to keep the strings from slipping out of position. Click on the image for a larger view of the string guide.

[MWaldorf]

Thanks Danny. Fortunately I've got my '66 as a template for cutting the guide. But how did you find that picture? Not reading Japanese, navigating Fillmore's site is an adventure.

[MWaldorf]

Update - I got the string nut cut. I used a dremel with a cutting wheel and it when pretty well. Here are some pictures.

First, a top down shot of the full barrel sitting on the neck. You can see the neck is a bit wider than the barrel; this is also the case on my '66.


Here's the full barrel seen from the side.


Cutting in process. As mentioned, I used a dremel with a cutting wheel. I held the barrel with a vice-grip, using a piece of a dremel sanding disc around the barrel to keep the vice-grip from making marks on the brass.


End results of the cut. It was a pretty clean job, though one side is a full half barrel and the other side is smaller, a half minus the width of the cutting wheel.


Here's the larger half on the guitar - the guides are lower than the zero fret but higher than the wood lip on the fretboard, so I think I'm in business.