DIY radius gauges

[WeirdBits]

As per Gav's request…

Two ways to make your own neck radius gauges.

First way, the easy one. Simply grab the Pickguardian Radius Gauge templates that Brendan found, then print them out… making sure that your printer is set to no scaling or 100% scale, and any 'fit to page' settings are unchecked (otherwise the printed radii will be wrong). Once they are printed check that the 1" scale measurement is actually 1", this is essential for the templates to be accurate (see pic below).

Then just laminate them and cut them out, or my preferred option would be to glue, tape or otherwise affix the templates to some plastic like an ice-cream container lid and then carefully (and accurately) cut them out with a hobby/x-acto type sharp knife. Ta Da! Radius gauges.

[WeirdBits]

Now, the harder way… ideal if you don't have a printer etc.

First, get yourself a length of something like plywood, it needs to be stiff but not too thick, ideally it should be around 24" (610mm) long (pic 1). Mark a centreline along the length of the strip and then a zero point at one end (pic 2), this will be your 'pivot' point. Then from that zero/pivot point measure and accurately mark points on the line at 7.25", 9.5", 10", 12", 14", 15", 16", 17", 20" or any other radii you want (pic 3). Then find yourself two small nails and a drill bit slightly thinner than the nails (needs to be a tight fit). One nail will be your 'pivot' and the other will be the 'scribe', ideally you should sharpen the scribe nail into a nice sharp *centred* point (ie. not skewed to one side). Then, carefully and as accurately as you can drill exactly on the centre of the zero/pivot point and at each of your radii marks (pic 4).

Push/tap your pivot nail through the zero/pivot point hole and, ideally, slightly into your bench… this must remain fixed and able to pivot to scribe your arcs (pic 5). Ideally, you want some plastic like an ice-cream container lid (soft but stiff) to use as your gauge, and them mark a square of around 70-80mm square on it… this will be the size of your gauge. Use your scribe nail to mark/dent in each corner of the square (to use as alignment). Insert your scribe nail through your required radius mark in your plywood strip, you want it you just have the point poking through. Position the plastic on your bench so that the scribe nail for your selected radius sits in the mark/dent of one corner of your gauge, then adjust it until the scribe's arc will line up with the opposite corner. When the plastic is lined up with the scribe's arc, tape or clamp it in place (pic 6). Then, carefully and slowly scribe your arc onto the gauge… if you've made your scribe nail sharp enough it should almost cut through the plastic after just a few passes (pic 7). The important thing is to keep the plywood flat with just the tip of the nail exposed, so that it cuts an accurate arc that can finished up (carefully) with a sharp thin knife. Then write the size of that radius onto the plastic (it can be hard to tell them apart).

Repeat the process for each side of your gauge with your preferred radii, repositioning and realigning the plastic each time.

If it all goes to plan you should soon have you own, reasonably accurate, radius gauge (pic 8). And, just for good measure, testing my new gauge on a Pit Bull TL-1A neck… nope, 16" doesn't seem to fit, gaps are showing (pic 9), ah perfect, 12" seems to be the one, no gaps, no light showing through (pic 10).

[dingobass]

Or you could get a set of radius gauges from stewmac for around the $20 mark.
Made of steel they will last forever! :P

[WeirdBits]

Yeah, got them too (love the understring gauges).

[Brendan]

But where's the fun in just buying them when you can make some? Naah - for us first timers that have got the bug, but not bad yet, it comes down to convincing the War Office that you need another kit or some fancy tools... I'll work on a few new tools per kit and take it that way.

Great plan Scott - may make some up in my spare time (...).

[dingobass]

It is a great idea to make your own tools, it does give you a greater understanding of how they work.
Also it may lead to improvements

[Gavin1393]

Awesome!

Thanks Scott. This is great! I get it now...struggled with the concept yesterday. No engineering DNA in me I am sorry to say!