Two-Step Cutaway Bending

by John Calkin

Originally published in American Lutherie #78, 2004 and Big Red Book of American Lutherie Volume Seven, 2015



Bending a venetian cutaway with a particularly tight horn presents a challenge. At Huss & Dalton we tried several times to alter our Fox side bender to reliably create tight cutaways, but with very little success. The add-on bending unit usually seen on benders worked well for blunt cutaways, but when the radii got small, the bender crapped out. OK, this admittedly depended on the type of wood involved. Indian rosewood is so accommodating that we often got away with completing the whole job on the Fox bender. Mahogany wasn’t quite as obliging but is cheap enough that an occasional broken side is no reason for tears. Koa was the driving force behind our search for a better system. It was frequently requested by the discriminating fingerstylists who seem to be the guitarists who want cutaway guitars in fancy varieties of wood. Killer sets of koa are also very expensive and become more so every time they are ordered. Other curly woods are just as hard to bend, but a broken piece of fancy walnut (just to pick a species) isn’t the heartbreaker that shattered koa is. The H&D model MJC was our particular bugaboo. Other builders use tighter cutaways, but the MJC was plenty tight enough to drive Jeff (Huss) and Mark (Dalton) close to distraction. There were frequent war councils among shop members about how to conquer the problem, but most of the ideas and all the tool making fell to Mark.

The problem wasn’t bending the horn itself. The spring-steel slats of the bending sandwich supported the wood as it went around the horn enough to prevent breakage. It was the inside bend of the cutaway that caused all the problems. The slats simply couldn’t be pulled tight enough during bending to support the wood. There’s no need to elaborate on the failures. Eventually a bending machine was made dedicated to the MJC (Photo 1). Various methods of bending the wood around the cutaway shoe were tried to no avail. The solution turned out to be bending the wood in two stages.