Early & pre 1973 cast aluminum saddles

[Kopfjaeger]

My intention is to speak to a few local machinists about manufacturing via CNC mill, several sets of aluminum saddles. If that looks to be very cost prohibitive, I may look into having someone cast them.

here is my question, The new zinc saddles are very defined with two distinct angles on their face. The cast aluminum ones off my 1965 4001 also have two distinct angles but there is no consistency between the 4 of them. I epoxied the very deep string grooves in them since the E string was nearly cut in half. i really don't know how it id not split in two due to the depth of the cut.

Here is my question, in order to get a consistent and true example to replicate, would it work if a new zinc saddle was the example with a modified adjustment screw location to mirror the cast aluminum ones?? I realize a minty aluminum saddle would be the ideal example to reproduce but I don't have a minty one nor do I expect someone to loan me a minty one, although I'm quite trust worthy.

Thoughts??

Sepp

[teeder]

I've had plans to do this, but just haven't got around to it. What I was going to do was measure a handful of the old saddles and make a drawing using "average numbers. Then have a local shop make them for me. It shouldn't be cost prohibitive if made in a batch. For example: here are the saddles they made for me on the 8 string bridge project I did a couple years ago.

Keep in mind, there's a lot of hand finishing on the old aluminum saddles. That's why they vary so much.

[johnallg]

I'll play devil's advocate and ask how do the Allparts saddles compare to the Rick ones for size and hole location?

[Kopfjaeger]

I'll play devil's advocate and ask how do the Allparts saddles compare to the Rick ones for size and hole location?

Good question John. I wonder if these interchange with RIC bridges. The chrome look of them has me wondering what they are made of as well.

Sepp

[Seans]

Casting would be the only correct way to go. The early saddle is not so definite in angle/shape as the later Zinc versions because of finishing polishing etc, pick a good one and go for it, don't forget to add 4% to the size of the buck though.

As for hole location, leave that to us that are fitting them, easy.

[Kopfjaeger]

I was visiting with several friends this weekend when I remembered one of them is practically finished with school to be a machinist. I ran my idea past him and he feels it's very doable. I wish I would have remembered his new trade so I could have brought a saddle or two to show him. He needs to see one so I'm starting with fotos. He will need to have one in his hand in order to know for sure and here is where it gets messy. I'm not willing to hold up my 4001 project while he screws around with the saddle. Since I don't have a spare to send him, how acceptable would it be to have a newer style replicated in aluminum?

They seem to shape quite easily so sanding it down to vintage spec should not be too hard. The hole set up in my bridge seems to vary a bit. Some of the chamfering seems to meet the top edge on some but not on others. It has been mentioned to leave the threaded intonation hole out of the saddler so they can be custom fitted. As long as you have a drill press this is a piece of cake to install.

Thoughts please on both omitting the threaded adjustment hole and the idea of a modern saddle shape being used as as prototype.

Sepp

[walker]

Great project, Joe. I'm looking forward to seeing what solution works out best. The aluminum saddles are indeed very shapable. I grinded/sanded down the length on one to get it to fit closer to the front edge of the bridge.

[RickyBubba]

Although casting is the correct way to go, the cost is going to skyrocket.

A good shop should be able to source some bar stock very close to dimension, then mill out the saddles.

First option is good old fashioned machine work with cutting bits. CNC is the modern version.

Another option could be cutting them on a "wire EDM" machine. It is similar to cutting foam shapes with a hot wire, just done on metal. Could require less hand work to clean up, but depends on the aluminum they choose and how it cuts.

Shop around, folks are generally hungry for work these days.

[teeder]

The saddles I had made were done in stick form and then just parted off. They required very little finishing.

[Kopfjaeger]

Guys,

The machinist "in training" is a family friend, actually he is more like my little brother so I doubt he'd even charge me. I'd of course pay him for his trouble especially if they turned out well. This kid does not know how to be bad at anything so I have no doubt they'd turn out well. If they did not not, there is no way in hell he'd hand me a lousy product. He'd scrap them and tell me he could not do it before giving me a shoddy saddle.

That being said, I'm sure they would be inexpensive when finished. I plan on asking him make 100 (25 sets). The important question is, if I give him a brand new zinc saddle to replicate in aluminum, without the threaded adjustment hole, would pre 73 4001 owners be interested in using them?? I can't spare a saddle from my 65 to loan him.

I'm not looking to make a profit on these, I'm really not. I'd like to have a few sets as spares and the rest would go to who wants them as long as I cover whatever I paid out of pocket for materials and his time.

Sepp

[Colonel Sanders]

Guys,

The machinist "in training" is a family friend, actually he is more like my little brother so I doubt he'd even charge me. I'd of course pay him for his trouble especially if they turned out well. This kid does not know how to be bad at anything so I have no doubt they'd turn out well. If they did not not, there is no way in hell he'd hand me a lousy product. He'd scrap them and tell me he could not do it before giving me a shoddy saddle.

That being said, I'm sure they would be inexpensive when finished. I plan on asking him make 100 (25 sets). The important question is, if I give him a brand new zinc saddle to replicate in aluminum, without the threaded adjustment hole, would pre 73 4001 owners be interested in using them?? I can't spare a saddle from my 65 to loan him.

I'm not looking to make a profit on these, I'm really not. I'd like to have a few sets as spares and the rest would go to who wants them as long as I cover whatever I paid out of pocket for materials and his time.

Sepp

Hi Sepp, I would chip in for one or two sets.

Thanks for this offer!

[chefothefuture]

Guys,

The machinist "in training" is a family friend, actually he is more like my little brother so I doubt he'd even charge me. I'd of course pay him for his trouble especially if they turned out well. This kid does not know how to be bad at anything so I have no doubt they'd turn out well. If they did not not, there is no way in hell he'd hand me a lousy product. He'd scrap them and tell me he could not do it before giving me a shoddy saddle.

That being said, I'm sure they would be inexpensive when finished. I plan on asking him make 100 (25 sets). The important question is, if I give him a brand new zinc saddle to replicate in aluminum, without the threaded adjustment hole, would pre 73 4001 owners be interested in using them?? I can't spare a saddle from my 65 to loan him.

I'm not looking to make a profit on these, I'm really not. I'd like to have a few sets as spares and the rest would go to who wants them as long as I cover whatever I paid out of pocket for materials and his time.

Sepp

Hi Sepp, I would chip in for one or two sets.

Thanks for this offer!

Hey Sepp-
I'd be interested as well
I've got a few basses with saddle alignment issues…..

[henry5]

The guy who made my last set no longer has access to the equipment so I'd consider some as well...

[leftybass]

I have said it on another thread but I'm in for a set as well.

[DriftSpace]

I also said it before, but just for the record: I am also in for a set of these.