Yamaha FG-411 VS - Cracked Headstock - Part 2

◀ Part 1

Preamble

After much research, discussion and experimentation, it's been decided that the most sturdy repair would involve countersunk screws, wooden plugs, and a healthy amount of Titebond Wood Glue. Besides crack repair, we'll also be cleaning/conditioning the fretboard and polishing the frets.

Yamaha FG-411 VS - Cracked Headstock

 

Reinforcement Screws

The most suitable screws for this repair are pickup height screws, and four have been carefully chosen based on their threaded length and diameter. These screws will be countersunk, and the resulting voids plugged.

Four Reinforcement Screws

Pilot Holes Drilled

Test-Fitting the Screws

Titebond to the Rescue

Now, the reinforcement screws will only be installed after the application of glue. Yes, it's time for some Titebond Original Wood Glue. To help force the glue deep into the cracks, I'm making use of an aquarium suction cup.

Titebond Wood Glue Applied

Forcing Glue Into the Cracks

Reinforcement Screws Installed

Plugging Voids

Remember those four countersunk screws? Those voids need to be plugged, and here's where wooden dowels come in handy. Saw off a suitable length, taper one end, apply glue, gently tap in until firmly seated, and leave overnight. The next day, saw off the excess, tape off, and carefully trim until flush with the surrounding wood. It's basically the same process for the six existing tuner screw holes, except that the plugs are bamboo satay skewers.

Reinforcement Screw Holes Plugged

Trimming the Plugs

Plugs Trimmed Flush

Existing Tuner Screw Holes Plugged

The Home Stretch

As can be seen, the rosewood fretboard is full of gunk, while the frets are badly tarnished. Servicing the frets will involve initial cleaning with a rotary tool, followed by polishing with Scotch-Brite pads. As for the fretboard, it needs to be scraped, cleaned with naphtha, and conditioned with lemon oil. However, I'm putting off conditioning until just before restringing.

Fretboard Before Servicing

Cleaning the Frets

Scraping the Fretboard

Polishing the Frets

Cleanup With Naphtha

Now that the fretboard and frets have been taken care of, it's safe to lightly stain the wooden and bamboo plugs, seal the affected areas with a coat or two of Minwax Antique Oil Finish, install new tuners, and condition the fretboard with lemon oil. 

Sealing the Headstock Plugs

New Tuners Installed - 1

New Tuners Installed - 2

Conditioning the Fretboard

Fretboard After Conditioning