Body Preparation

• 1). Open your lunchbox and line up the poplar board under the lid of the lunchbox. The length of the board should be parallel with the long side of the lunchbox. There should be two inches of board showing past the end of the lunchbox lid. Mark the board on either side of the lunchbox lid. When the guitar is finished, the lunchbox will close over the poplar board. The poplar board will become the neck of your guitar, and the lunchbox will be the guitar body.
  
  
• 2). Thin the section of guitar neck between the marks. Use a wood file to gradually remove wood from this area of the guitar neck. Remove just enough wood to match the depth of the lunchbox lid. Sand the finished groove with fine-grit sandpaper.
  
  
• 3). Cut two notches in the lunchbox body to accommodate the back of the guitar neck. The notches should be just deep enough so that the neck fits snugly in the lunchbox when the lunchbox is closed. Cut the notches out with a hacksaw or a pair of metal snips, and file the notches smooth with a metal file.
  
  
• 4). Drill four half-inch sound holes in the lid, two on each side of the neck notches.
  
  

Neck Preparation and Assembly

• 1). Mark the top of the neck four inches from the end of the board. This mark will divide the headstock from the fretboard. Drill three holes in the headstock, sized to match your tuning pegs. Offset the three holes from each other so that the strings will not touch when the guitar is strung.
  
  
• 2). File the headstock with a wood file until the front of the headstock is about a quarter of an inch shallower than the fretboard.
  
  
• 3). Drill three small holes in the bottom of the neck, about a half-inch from the bottom. The holes should be just large enough to accommodate a guitar string. Cut a round groove in the top of the neck, a half-inch below the headstock. The groove should be just deep enough so that the bolt will sit in the groove with two-thirds of the bolt protruding above the surface of the neck.
  
  
• 4). Apply a thick, even coat of contact adhesive with a foam brush to the areas of the neck and guitar body to be joined, and clamp the neck in place. Allow the guitar to sit for 24 hours before unclamping.
  
  
• 5). Close the lunchbox lid over the glued neck. String the guitar strings through the holes at the base of the neck. Insert the tuning pegs into the drilled holes on the headstock. Slide the eyebolt under the strings at the base of the neck, and twist the strings around the tuning pegs. Slide the bolt into its groove just below the headstock, and tighten the strings to the desired tuning.