The headstock of this J-45 was brought to me like this.
A successful headstock repair comes from getting a strong glue seam between the headstock and neck. Usually, it is a relatively simple process of gluing and clamping the two pieces together. In this case, there's not enough surface area to get a bond strong enough to support string tension. Also, there were additional pieces missing that would need to be filled. The solution? Create surface area by sanding the neck and headstock, then join them together with a piece of mahogany. Simple, right?
First, I get a rough surface area started by using a rasp.
Next, I use a sanding block fabricated for this repair to get a nice, flat area around the truss rod.
This is roughly how the pieces will be situated once joined together with a third piece of mahogany.
After many test fittings to ensure that the headstock is aligned perfectly with the neck, the fabricated piece is ready for gluing. Notice the pinning rods to help hold correct alignment.
After gluing the piece to the headstock and additional test fittings to the neck, I install pinning rods to ensure that the alignment will be perfect.
The gluing was successful, and the angle and alignment came out just as planned. Now to make it look like a guitar...
Various stages of shaping the adjoining piece.
Ready for color.
Ready for gloss finish.
After putting on the tuning machines and a simple setup, this guitar will be as good as new!