US Amazon Prusacaster Core

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Update for just “black_core” remix 4/14/2023

I updated the remix of the “black_core” to include the holes for the original “pickguard" designed by  Mikolas Zuza's.  

• Very Important:
  • For compatibility with “The Prusacaster - a 3D printable guitar”:
    • Use “Remix black_core with pickguard holes.stl"
  • For the Gibson SG Standard/Telecaster hybrid:
    • Use “RemixUS-PrusaCaster-black_core.stl”
       

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Original Post

Remix: I utilized Mikolas Zuza's “black_core” model for compatibility purposes, only measuring the outline of his original “black_core” model.

I have completely remade the “black_core” model using Onshape, and designed a hybrid guitar, to be compatible with a particular kit I personally purchased from Amazon: Fistrock DIY Electric Guitar Kit Tele Style Beginner Kit 6 String Right Handed with Ash Body Hard Maple Neck Rosewood Fingerboard Chrome Hardware Build Your Own Guitar., DIY STL 120-Ash-A.  

For those of you that just need the “black_core” US remix you can ignore the rest of the files. The “black_core” remix will fit the rest of the “The Prusacaster - a 3D printable guitar”.

• Pick Guard notes:
  •  There are two pick guard holes on remix based on the US kit I received.
  • I am not certain if the pick guard that came with this kit or the “The Prusacaster - a 3D printable guitar” “pickguard” will be a perfect fit.
    • (I did not use either of the pick guards, designed my own)

For measurements that I took, and models I designed from this particular Kit see my other models: 

1. guitar-pickup-mount-for-measurement-purposes-only
2. US Electric Guitar Neck and head -- For Measurement purposes only

I recommend checking your measurements even if you bought the same kit I did.
Why I ultimately remixed the “black_core” was two reasons:

1. Neck of my guitar would not fit
2. Guitar lower pickup mount did not match:
   1. Three holes versus five,
   2. Holes did not line up.

For those of you that want a Gibson SG Standard/Telecaster hybrid see the rest of the files.

•  I wanted to make an electric guitar similiar to the film “School of Rock (2003)”, for a family member who is disabled and is a huge fan of Jack Black. 
  
  • About My photos as of the original posting: The parts need post processing, sorry for the sanding marks and glue all over. 
    • I didn't want to upload the gcode and the lithophane with Jack Black on the pick guard.  However I did upload a non lithophane version.

— Update 04/09/2023 --  No changes to model just updated pictures with my progress of post processing, (still a work in progress as far as post processing). 

 Used Bondo, sanding, paint, primer and clear gloss.

Don't use string to hold your prints when painting, I learned the hard way… the string snapped…

Since the string snapped, I had to cut and remove sections of the print, sand and a lot of Bondo… I then used a sturdier metal wire to prime, paint and gloss.

These are where I left off today, I'm not sure if I want to buff the gloss or not or leave it as is. 

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update 4/16/2022
Finished post processing, I've never done this before, but it was a lot work but I think it was worth it.




 

The products that I used:
 JBWeld Plastic Bonder (for glueing parts together initially, not in above picture),
Bondo All Purpose Putty, (filling gaps, and in my case when the string broke),
Wet Dry Sandpaper; grits (60, 80, 150, 220, 320, 400, 600, 800, 1000, 1200, 1500, 2000, 3000),
Acetone, (for cleaning area after it broke so bondo could bond),
Rust-oleom; 
Plastic Primer (2 light coats)
2X ultra cover paint + primer gloss, purple (3 + another 2 coats since I had to do it over again),
2X ultra cover gloss clear, (3 + another 2 coats again because I had to do it over again),
Sanding block/sponge, (400 - 3000 grit wet sanding),
Turtle Wax Rubbing Compound heavy duty cleaner,
100% cotton cleaning cloths, (for applying Turtle Wax products)
Scott Shop Towels, (Lint free, really nice to have but not needed),
Turtle Wax Polishing Compound light to medium cleaner,
Turtle Wax Scratch Repair & Renew,
6 inch wool polishing buffing pad with drill adapter.
 

• My post processing steps: 
  • after JBwelding guitar together and bondo, I used 60-80 grit hand sanding,
  • primed guitar (don't use string like I did, use something stronger),
  • Paint, then gloss,
    • let dry for a 24 hours inbetween
  • wet sand using sanding block wraped in a wet shop towel. 400-3000 grit,
    clean surfaces,
  • applied rubbing compound with clean cotton cloth, circular motion, then buff,
    • repeated twice,
  • applied polishing compound with clean cotton cloth, circular motion, then buff,
    • repeated twice,
  • applied scratch remover with clean cotton cloth, circular motion, then buff,
    •  repeated twice.
  • wiped down excess with shop towels.
    
     

How to create a custom lithophane like the one I used for the pick guard:

1. Find an image you would like to use for the lithophane.
2. (Creating an lithophane)
   I utilized https://lithophanemaker.com (free as 4/24/2023)
   1. upload desired image
   2. for “Frame Options” I used:
      1.  “No Border”
   3. for “Lithophane Resolution (mm/pixel)” I used:
      1.   0.2
   4. Width and height will depend on your desired image
   5. for "Maximum Thickness (mm) I used:
      1.    2.00
         1. This is the the thickness of my my pick guard model
   6. for “Minimum Thickness (mm)” I used:
      1.    0.2
   7. Then click “Create .stl” button to download the generated lithophane.
       
3. (Slicing)
    I utilized PrusaSlicer Version 2.6.0-alpha5 to add a negative volume to the pick guard.
   1. First add PickGuard.stl in PrusaSlicer.
   2. Make sure you PrusaSlicer mode is set to “Expert” mode.  (Button located at the top right of the PrusaSlicer)
      1. (This allows you to have more than one object PrusaSlicer, which in this case we will at least need two objects.)
   3. Ensure you have the “Plater” tab option selected, (located on the top left of PrusaSlicer).
      1. Located on the right side of Plater view there is a section that has fields “Name" and "Editing” (this is just below “Infill” and “Brim” options) find “PickGuard.stl” and:
         1. Hover over with mouse cursor and Right click it, (this will open a context menu for the “PickGuard.stl”)
            1. Within the context menu hover over:
               1. “Add negative volume” (a sub context menu should appear)
               2. in the sub context menu click “Load …”
               3. Select your lithophane stl file (from step 2:7).
   4. Position your lithophane to your liking on the pickguard,  in my case I had my lithophane stl Z “World coordinates” 2.06mm floating, (I had to reslice over and over until I found what I personally liked).
      1. (Just an observation the pickguard Z “World coordinates” position is set to 1mm, incase you are wondering why the math doesn't seem to make sense, as I was confused as well, but the “Object coordinates” seem to make sense.)
   5. (optional) Once you are satisfied with positioning, and have sliced the stls, and if you don't have Prusa MMU (like myself), you can add colors changing gcode instructions by following this handy article:
      1. https://help.prusa3d.com/article/color-change_1687
      2. I changed my colors to roughly see what it would like in the end rather than having PrusaSlicer set the default colors.
   6. Print!  (if you don't have the MMU and decided to use multiple colors stay near by your printer for color changing prompts.)