Workshop Journal Vol. 1 • Issue 6

ReSound'65 | Workshop Journal

Vol. 1 • Issue 6

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The Art Of The Craft

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The cycle of production continually loops through the many stages of manufacturing. As you follow these journals, you will encounter moments when certain guitars are just beginning their journey while others are nearing completion. Our workflow moves in and out of sequence—as batch manufacturing naturally does—with multiple groups of instruments advancing through the shop at the same time.

This week, a new load of bodies is in!

The meticulous process of building an amazing guitar begins with accurate CAD files for the CNC machines that transform raw materials into precision components. This is where the fit and finish we expect from every ReSound'65 first begins to take shape.

Once the parts come off the CNC—whether wood or aluminum—all critical dimensions must be confirmed. If a part is out of tolerance at this stage, the problem will only become more pronounced downstream, potentially creating significant complications later in the build.

Today, we are checking all the hard maple components to confirm their accuracy and ensure they meet our established tolerances.

Once those inspections are complete, we can begin sanding and preparing the wood surfaces so everything is level, smooth, and ready to fit as engineered. Our CNC machines do a remarkable job, but nothing replaces a skilled human hand when it comes to removing the final burrs, splinters, and imperfections.

Wood is temperamental. It must be sealed to prevent moisture and other contaminants from interfering with the surface and grain. The sealer also creates the necessary foundation for the nylon flocking process that will take place later.

After the sealer is applied and allowed to cure, the surface is sanded smooth to remove any dust or debris that may have settled during the drying cycle. Every edge is inspected and prepared before we proceed to the next stage: lamination.

This portion of the process demands close attention to detail. Once the wood surface is clean and properly prepared, the Formica laminate can be applied—but first, every piece of laminate must be carefully inspected for scratches. The factory covers each sheet with a protective PVC film, but we have learned the hard way that protection does not eliminate the need for inspection.

The laminate is cut down to size, and then the adhesive process begins. At this stage, even a single contaminant—a speck of sawdust, dirt, or dust—can become trapped between the wood and laminate and create a visible dimple in the finished surface. A clean, dust-free environment is absolutely essential.

Once the laminate is applied, we use a router to remove the excess material. Every seam is then inspected for proper fit and adhesion. The edges are carefully dressed with a file, ensuring every corner is eased, smooth, and beautiful.

If we discover a scratch, crack, or flaw, we start over and make it right. Fortunately, that happens far less often when good craftsmen are building the guitar!

Elsewhere in the shop this week, cases are also in production. Case building is a continuous process because no guitar can be shipped or delivered without one. We have designed a beautiful crushed-velvet interior with generous plush padding to protect our instruments and provide lasting peace of mind during transportation.

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Custom guitars introduce another layer of planning and craftsmanship. After the customer selects the colors and inlays, we begin color testing and producing mockups. It is important to confirm that the colors work together and achieve the desired design before moving forward, ensuring that everyone is happy with the final result.

Today, we are developing a Deep-Sea Blue Flame Maple finish with diamond inlays.

The first step is to apply black dye, allow it to dry, sand it back, and then apply the blue. This stage requires finesse and patience because color and wood grain react differently on every guitar. It is not an exact science, which is why creating samples and securing approvals is such an important part of the process.

This week, we began developing that sample. Next, we will apply the clear finish to reveal the rich, dynamic “pop” within the flame maple grain.

Stay tuned for the next Workshop Journal as this striking custom finish begins to come alive.

#ReSound65 #WorkshopJournal #EmmonsGuitarCo #TheFaceOfAnEmmons #PedalSteel #SteelGuitar #AmericanCraftsmanship #MadeInUSA #BuiltByHand #ShopJournal #CustomBuilt #PrecisionCraftsmanship #LegacyContinues #ProductionCenter 

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