I'm back! Pardon the long delay, life gets in the way of the fun stuff.
So with a long overdue update on this project:
One of the surprising setbacks on this project was matching the body roundover to match the factory contours (especially important since there needs to be a smooth transition from the original roundover to the new half, on each side of the body.
I found a few threads on OSG that specifically said the JM body has a 7/16" roundover. This is an unusual bit size, but I found one and gave it a shot.
The result:
totally wrong. The 7/16" roundover leaves a sharp edge on the side of the body and wasn't deep enough to match the original edge.
(Original backside roundover on top, new addition on the bottom):
The original roundover on a pre-CBS Jazzmaster is 1/2" (which completely makes sense, it's the same as on Strats, P-Bass, Mustangs etc. Why would Fender use more than one roundover bit size?)
After swapping out for a 1/2" bit, everything started to look right. Finished the edges, and feathered everything by hand-sanding. Overall, looking really good. I have a bare 1964 Jazzmaster body here to compare against, and the contours are a perfect match:
I'm jumping forward a lot here, since I subsequently sanded the body by hand from 180 grit to 220, 320 and finally 400 grit in prep for sealer coats. I was able to get *most* of the old red finish off, and the cavities clean, but the red had been applied after the fullerplast was stripped, and sunk into the grain to some extent. This is going to be a solid color anyway, so there's no need to waste time getting paint out of every pore.
First I laid down a coat of Mohawk lacquer sanding sealer, waited for it to dry, and then blocked it with 400-grit dry.
Then I laid down a couple thin coats of Mohawk white sanding sealer/primer. Looking pretty good, none of the seam lines are visible in the slightest.
At this point, my work with the guitar is nearly finished. I'm not really equipped to do complete lacquer painting at home, and want to send the guitar out to get the final color and appropriate finish aging (to match the condition of the guitar's original parts). I've settled on
Sherwood Green metallic with matching headstock and mint guard for this guitar. Basically back to looking like a normal factory '62 JM in a custom color.
No idea how long it will be until I get the guitar back with color, but I'll document the final assembly here. Stay tuned!