Jem Style Handle

by Brian Calvert

You will need a few more specialty tools to create this part of your project and they will be suggested as the tutorial takes place. First of all grab a Square and measure from the very tip of the Upper Horn down 5 1/2" parallel to the center of the body and make a mark 5/8" from your line of measurement in towards the center of the body (As viewed on the left photo below). This method works for both AANJ and Standard Neck joint bodies so don't panic.

The right photo above shows what you are after. Mark a Line Parallel to the center of the body from the beginning point you just marked. From that make a second line parallel to it 1/4" in towards the center of the body and a third 3/32" beyond that line. Now make a line 90 degrees from your first mark across the other two lines and using it as a starting place draw a second line below it 27/32" down. From this line draw a third one 1" below and follow up with a fourth line which will be 13/16" below. The first center spot for the first hole you will be drilling out is of course the starting point you located when you began. The second center is located 1/4" in and down 27/32". For the third center point you will have to drop down 1" and go in 3/32", and finally the forth holes center will be located by dropping down the final 13/16" but moving back to the 1/4" marked line. Time to take out your trusty nail or punch and make starter marks at all four of these locations (as viewed on the left photo below).

Looking at the right photo above you can see that I have drilled out pilot holes for the bigger drill bits to follow. Now you have a choice to make. You can use either a 15/16"(used for the first 3 holes) and a 3/4" flat bladed drill bit made for cutting wood or go with a 1"(used for the first 3 holes) and 3/4" hole saw bit which will give you a much smoother edge. I prefer the hole bits myself as the wood bits do tend to leave the surrounding surface very messy all the way through the body. I know your wondering why two sizes well the 3/4" bit is for the very last hole ( the one located furthest away from the horns of the body). Start your drilling from the top and go about 3/4's of the way through the body and them flip it over and continue your cuts of all of the holes from the reverse side (as viewed on the left photo below).

Now that you have all the holes drilled out place your body on a 2"x4" and draw a line along the edge and cut out that piece of wood (the idea here is to build a support jig to hold the tools level while working on the side of the body) You will need to find a scrap piece of wood that is about 1/4" thick to staple or glue to the base of it in order to get the proper thickness of the body itself (as viewed on the left photo below).

Using the jig you can properly support a scroll saw to make the cut along the body at the base of the handle to eliminate the ridges of the original holes as shown in the photo on the top right. If you have one of those vibrating table top scroll saws with the thin 6" blades attached through the table you could place the blade inside the holes and make this same cut which is an option at this point. Now take out your router and a flat cutting bit and set it to a depth of 5/8" (as viewed on the left photo below).

Using the jig you made as a support draw and cut the handle out with your router as viewed in the right hand photo above. Now flip the body over and inspect your work so far, I left the jig in place so that you would get a better idea of what it looks like next to the body (as viewed on the left photo below).

Using a flat bladed File smooth out and round out the inside of the grips on your handle as viewed in the photo on the top right. Now your ready to do the finishing work on your handle. Using a mini 1/8" outside cut round router bit ( I prefer Dremels for this) go ahead and smooth out around the front of the body inside the handle (as viewed on the left photo below).

Soon you won't think twice about doing this to all of your body's as it really is not as difficult as you might think as long as you have the proper tools. Good luck!