Brian May Red Special Guitar Build Project: Making the Truss Rod by dsgb

Brian and Harold May fashioned a single action compression style truss rod for the famous Red Special guitar from a length of 3/16" diameter steel rod using their kitchen gas stove. This video illustrates all the equipment required, and processes involved in making a similar truss rod for a Red Special replica guitar. The time-indexed list below will allow you to skip to particular sequences, most of which are shortened for brevity except sequences 1 (introduction), 16 (bolt/loop fit check) and 17 (dual action truss rod) which contain commentary.
Notes and Disclaimers
1. Please note that I am an amateur/hobby luthier and therefore not proficient in any of the illustrated metalworking techniques (hot forging, brazing and thread cutting). I only learned enough to make a few of these truss rods to a reasonable standard with basic workshop equipment and limited facilities so if you wish to see these techniques demonstrated skilfully by experienced professionals, please seek out appropriate instructional videos elsewhere.
2. At the end of processes, I screw a stainless steel M5 sleeve nut onto the threaded end. I do not illustrate the process of cutting two orthogonal slots into one end with a grinding disc or hacksaw to match the original piece. This will create a castellated style nut which can be adjusted with the appropriate tool, if required.
00:01 - Introduction
01:56 - Inserting the bolts for the first bend
02:10 - Setting up the OxyTurbo gas welding set - lighting and regulating the flame
02:57 - Hot forging the first bend
04:06 - Showing the rod after the first bend
04:14 - Inserting the bolts for the second bend
04:31 - Hot forging the second bend
04:54 - Releasing the rod after the second bend
05:02 - Showing the rod after the second bend
05:10 - Brazing preparations 1 - Smoothing indentations with a diamond file
05:21 - Brazing preparations 2 - Removing oxidation with 180 Grit abrasive paper
06:03 - Brazing preparations 3 - Degreasing with isopropyl alcohol (IPA)
06:22 - Brazing preparations 4 - Making up borax flux paste
07:07 - Brazing preparations 5 - CuP Alloys brazing rods
07:15 - Brazing the loop closed
07:45 - Post brazing clean-up
08:24 - Grinding a lead-in for the thread
08:37 - Cutting the external thread on the truss rod
09:25 - Bolt/loop fit check
10:44 - Dual action truss rod
Please check out my other RUclips videos and visit my website, dsgb.net for a wealth of information on Brian May's guitars and musical equipment, event reviews and other guitar related projects.
#BrianMay #RedSpecial #dsgb #DougShortGuitarBlog

[@brianmaysguitar2]

What type of washer do you use for your truss rod? I have a square washer, but the one I see everyone use is rectangular and long. I can’t seem to find one of those. Thank you in advance.

[@dsgb]

Hi. If you are referring to the part that the sleeve nut butts against to adjust the tension, this is custom made from a section of 1/16" thick brass sheet.

[@brianmaysguitar2]

@@dsgb Ah, I see. Thank you for the response!! Guess I’ll have to stick with my little square washer then😂😂 or ask around the red special forum, or on other RUclips channels to see if I can get someone to point me to a similar one anywhere. thanks again for the response.