Manufacturing Thor: Mark II

I owe a great deal of gratitude to the owners of the first Thor batch for their patience and support for the project. There has been radio silence since my last Thor-related post in January 2023, but this is not due to inactivity. Rather, we have been working nonstop to complete the project. In terms of instrument construction, this is the final version that I am happy with. I am calling this Thor Mark-2. It is a milestone!

Manufacturing Thor: Part 7

Here’s how our fret cutting tool works. A laser-cut acrylic template with fret position slots aligns with a 3mm pin. The fret slots are cut on a small rotary saw with a titanium coated circular saw blade with a cutting width of 0.5mm.

Manufacturing Thor: Part 6B

After posting Manufacturing about Thor’s Compound Radius Fretboard, I was pointed to an article by Mottola stating that compound radius fretboards are not worth the extra effort and that cylindrical fretboards and normal fret dressing techniques yield the same results. I went on to analyze this claim.

Manufacturing Thor: Part 6

Thor’s fretboard has a compound radius, with a nut radius of 304 mm (12′′) and a 24th fret radius of 456 mm (18′′). Compound radius fretboards have a conical surface that allows for low action and no string buzz.

Manufacturing Thor: Part 5

Manufacturing Thor Part 5: The Neck Duplicator​: How do you quickly produce repeatably precise necks without using a CNC? We made our own wood carving duplicator for just this purpose. It works like a charm. It enables us to copy a master pattern in amazing detail using a compact router on one side and a stylus on the other.

Manufacturing Thor: Part 4

Part 4: The Nut​: OK, So… Your frets are metal. Your tuning machines are metal. Your bridge is metal. And your nut is… eh… plastic? Bone? Or some kind of synthetic material resembling bone? The nut we use for Thor is made of laser-cut stainless steel, buffed to perfection. It matches the sonic and mechanical properties of Thor’s stainless-steel frets.

Manufacturing Thor: Part 3

Part 3: Manufacturing The Middle Section Previously, I wrote about the design of the Thor’s middle section. This time, we’ll look at how the middle section is manufactured. As mentioned in the <a href=”” target=”_blank” rel=”noopener”>previous post</a>, I decided not to use a CNC machine. At least not this time. We don’t use much wood anyway, and the wooden parts are …

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