We take a "standard" tour of how guitars are made in Spain, obviously bearing in mind the many variables and methods depending on who makes them, from the different choices of materials to very different construction processes. Nevertheless, here we've followed a handcrafted manufacturing process for the Spanish or flamenco guitar.
How is a Spanish or flamenco guitar made?
Living up to its name, the Spanish guitar, most manufacturers and luthiers in our country have used the "Spanish heel" construction system since time immemorial. This means that during assembly, part of the neck ends up inside the body.
The Spanish heel
This system for joining the neck and body provides a sturdier construction than other systems, such as the "dovetail," which is very common in the furniture industry. The Spanish heel also gives the instrument greater durability and stability.
This type of construction is characteristic of classical and flamenco guitars made in Spain. In it, the neck has slots in the heel to receive the guitar's sides. The body is built around the end of the neck.
This system seems the most suitable for the neck/body assembly, although the fact that it takes more hours of work, and in turn increases the cost, has led several manufacturers (especially outside Spain) to abandon it. From the outside we can't tell which type of joint is actually used. But from the inside, through the soundhole, we can see a small part of the neck (the foot) resting on the back of the guitar, which also stabilizes the neck angle.
Manufacturing
Properly speaking, the manufacturing process starts with the wood selected by the master guitar maker, which is prepared through a long drying period. The top has an opening decorated with marquetry, whose look and design is generally one of the features that identifies the maker.
The top is prepared and glued, along with the wood-veneer rosette and the neck. Meanwhile, the neck is made by gluing on the headstock and the heel block. The process continues with the sides, which are bent and inserted. They're fitted into the heel while being glued to the top.
Finally, the tail block is fitted and both sides are joined at the bottom of the instrument (body). The linings are glued to the sides, and then the bracing is installed, which is fundamental, since it's responsible for projecting the sound the top produces. The arrangement, dimensions and material used for the bracing will have a lot to do with the instrument's sound.
Next, structural elements are used on the lower part (the back) to glue the guitar's "floor" in a solid, stable way.
Binding with cords
This involves tying a very taut cord so that the glue sets in each of the parts and they become a single, consolidated "unit." "Every craftsman has their own tricks," which means there are various ways of tying the cord. It will basically depend on the strength of the woods used in the construction.
Smoothing and preparation
After smoothing, the fingerboard is glued in place. Once this piece has hardened, the slots for installing the frets are cut. Finally, the neck and heel are carved.
Varnishing and polishing
The instruments are sanded thoroughly until the surface the maker intends is achieved. The different coats of varnish are applied, with progressive sanding between them. Then it's time for polishing and finishing the instrument as far as the wood is concerned. Hardware and strings: after polishing the fingerboard, the tuners are installed and the strings are fitted and tensioned. The guitar is tested, bagged, and the product is ready for the musician's hands.
