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Seth Newsome’s guitar combined a molded carbon-fiber composite body shell with wooden instrument parts, including its soundboard, headstock, fretboard, and bridge. In his May 6, 2015 Make: project account, he describes forming the shell over a cardboard mold, then fitting and finishing the instrument. It is a useful account of one workshop build—not a tested recipe for guitar acoustics or a universal construction specification.
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What made this a hybrid guitar
Carbon-fiber composite formed the body shell; wood supplied the soundboard and several central playing and structural components. Newsome modeled the body on a 1940 Gibson L-00 plan, then used his shell as the foundation for the wooden parts. The project therefore involved both composite fabrication and the precision work of building an acoustic instrument.
His account, “How I Made a Carbon Fiber Acoustic Guitar”, was published in 2015. It documents his materials, choices, and setbacks. It does not report controlled sound measurements or establish that this construction performs better than a wooden guitar.
#1 Best Overall
- One right-handed Fender California Debut Redondo acoustic guitar – a perfect beginner guitar for all ages
- Designed by the most trusted name in guitar and backed by a 75-year legacy of quality and craftsmanship
- This beginner guitar comes with a 30-day subscription to Fender Play that includes lessons with thousands of instructional videos to build your skills by playing the songs you love, all with no additional cost
- The California Debut Redondo Series Acoustic Guitar features the iconic 6-in-line Fender headstock shape and dreadnought body shape with a reslient laminate construction for durability
- The easy to play "C" - shaped neck, walnut fingerboard and light weight all-laminate body allow for a smooth and comfortable playing feel, and the sealed-gear tuning machines allow for accurate tuning, with a walnut bridge for optimal tone production
How he formed the body shell
Making a mold to suit the cloth
Newsome created a positive mold from stacked, laser-cut cardboard slices based on a 3D model. For his project, the model measured about 935 mm long, 358 mm wide, and 111 mm deep; he cut it into 56 slices across 23 cardboard sheets. These are dimensions and fabrication details of his particular guitar, not standard acoustic-guitar measurements.
He rounded the body sides rather than relying on sharp corners. Plain-weave cloth can resist conforming to tight transitions and tent away from the mold, so its drape influenced the shape. Where underlying layers lifted at a tight curve near the neck, he used relief slits and overlaps. He also softened a sharp transition with auto-body putty.
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- With a combination of reliable Fender quality, player-friendly features and attractive aesthetics, the all-new California Debut is a value-packed option for today’s acoustic player
- Designed for beginner's, featuring a durable all-laminate body crafted with premium tonewoods, and an easy-to-play “C”-shape neck with tilt-back 6-in-line headstock. With a walnut fingerboard for a smooth and comfortable playing feel.
- Further details include Dreadnought body shape, sealed-gear tuning machines for accurate tuning, a walnut bridge for optimal tone production, a smooth satin finish, and body and neck binding for added durability
- The CA Debut series packs premium Fender quality into an affordable beginner friendly acoustic guitar. The CA Debut series also ships with a free 30-day subscription to Fender Play & Fender Tune, so you can start learning from the comfort of your home the second you unpack your new guitar!
- 2-Year Limited Warranty: Fender guitars are built with unmatched quality, down to the last screw- which is why Fender warrants this Fender acoustic guitar to be free from defects in materials and workmanship for two (2) years from original purchase
Brushing on the composite
His layup used plain-weave carbon fiber, S-Glass as a less expensive filler layer, and marine-grade epoxy. He applied resin with a brush and gloved hands rather than vacuum bagging. He laid carbon fiber, then S-Glass, then another carbon layer, taking particular care with the outer, visible “show-layer.” He later added Coremat foam reinforced with S-Glass to strengthen flexible areas.
Newsome reported that the epoxy he used had a 4:1 resin-to-hardener ratio and a stated pot life of 20–30 minutes. Those figures apply only to the product in his account. Resin ratios, usable time, temperature limits, and cure schedules differ by product; follow the selected epoxy manufacturer’s current instructions and safety documentation. He recommended arranging the materials before mixing so the layup can proceed within the product’s working time.
Rank #3
- Complete Beginner Guitar Pack - Everything needed for starters is included, just unbox & play. The bundle includes Moukey 41” acoustic guitar, chord poster, 3mm padded gig bag, tuner, strap, capo, strings and picks. A decent gift for children, friends and family.
- Ideal for Beginner - With cutaway design, Moukey 41” acoustic guitar is easy for starter to learn. Dreadnought body provides a full and vibrant tone, suited for all styles of music. The precise position marks at 3th, 5th, 7th, 9th, 12th 15th and 17th frets on neck and top of fingerboard help the starters to learn conveniently.
- Come with Chord Poster - The ultimate beginner-friendly guitar chord poster shows the most commonly used chords, enabling starters to memorize fretboard and play chords on the first day.
- Exquisite Workmanship - Quality basswood body, Okoume neck, smooth fingerboard, and non--scratching frets enable Moukey acustica guitarra to be played comfortably for a long time. 2 strap pegs allow you to attach the strap easily.
- Stay in Tune - Constructed with 1:14 enclosed copper tuning machines, Moukey full size guitar can be tuned finely and smoothly without slipping. Along with hard bridge saddle and bone nut, Moukey guitarra acustica is easy to tune and hold tune after first tune-up of strings.
He said cold workshop conditions slowed his cure and that he used a low-setting powder-coating oven below 120°F to ensure it cured. That describes his procedure, not a general heating recommendation: use only the cure conditions specified for the epoxy you choose.
Releasing and reinforcing the shell
After releasing the shell from the mold, Newsome added Coremat along the edges and down the center from the neck. He placed S-Glass beneath the Coremat because it did not adhere well to the carbon fiber by itself. He then flattened the body and shaped a pocket to receive the soundboard.
Rank #4
- Perfect beginner guitar: Designed for students and teens who are just getting started. This 38-inch, right-handed, acoustic guitar features all the bells and whistles. Designed with 18 smooth frets, 6 pre-installed steel strings, and an easy to hold neck.
- Complete beginner kit: This all-in-one entry-level guitar bundle includes a 38-inch acoustic guitar, carrying bag, 3 picks (assorted colors), shoulder strap, extra strings, and 4 months of free app-based lessons (iOS or Android). The App features thousands of songs, step-by-step lessons for all skill levels, and a built-in digital tuner for easy tuning anywhere.
- Superior-grade tonewoods: Top, back, and sides are crafted from basswood for versatility and warmth, with a high-gloss finish. Whether playing soft or loud, strumming or flatpicking, this guitar remains responsive and retains its tonal integrity. This guitar is built to last.
- Incredible sound: Perfect for musicians-in-the-making, this beginner acoustic guitar features an impressive tone, bright sound, and standout projection. It's waiting to be heard.
- 38-inch beginner guitar: Measuring 38" (L) x 14" (W) x 3.25" (H), this beginner guitar delivers the timeless look and sound of a traditional acoustic guitar. Low string action helps reduce finger fatigue for easier playing and improved comfort while learning. Note: New strings may arrive out of tune, which is normal. As the strings stretch with use, the guitar will hold tuning better over time.
Fitting the wooden instrument parts
The shell did not eliminate the demanding parts of guitar construction. Newsome installed the soundboard, headstock, fretboard, and bridge, and emphasized the need for a proper guitar-building reference to place the bridge and lay out the frets accurately. He reported a 63 cm distance from nut to bridge for his design; it is not a general scale-length instruction. His soundboard measured 2.6 mm, likewise a project-specific measurement.
He used five-minute epoxy to attach these components, but the bridge began separating under string force after about a month. He planned to repair it with wood glue and a proper clamp. That outcome makes his initial bridge attachment a reported failure, not a method to copy. For construction details such as joint preparation, bridge attachment, fret placement, and clamping, he points readers toward a dedicated guitar-building reference. Newsome named Build Your Own Acoustic Guitar by Jonathan Kinkead, which he borrowed from his local library; the account does not establish its current edition or availability.
Finishing the composite
Newsome filled gaps with pigmented epoxy, sanded the composite, applied another gloss coat, then wet-sanded through progressively finer grits and polished with auto-body rubbing compound. Trapped bubbles left some areas cloudy, and he accepted some blemishes rather than achieving a flawless surface. He used a cedar soundboard and added CNC- and laser-made inlays and artwork.
What the project shows—and what it does not
- Shape depends on the layup. Mold geometry can open up different design possibilities, but tight corners may cause cloth to tent and require design changes or careful relief cuts.
- A molded shell is only one part of the job. Flattening the body, fitting the soundboard, aligning the neck-related components, laying out the frets, and positioning the bridge still call for instrument-building knowledge.
- Material claims need qualification. Newsome viewed carbon fiber as a way to make repeat builds more consistent and the shell less vulnerable to humidity than wood. He provided no comparative measurements, controlled acoustic test, or guarantee that a hybrid instrument’s joints are weatherproof.
- Access affects effort and cost. He found the body-forming stage accessible to a beginner and faster than traditional body construction, but noted that carbon fiber is not cheap. His laser-cut mold was inexpensive because he had access to TechShop; he did not report a total project cost.
Safety while cutting and sanding
Newsome advised wearing gloves and a dust mask—or preferably a respirator—when cutting or sanding. He also warned that cured composite fringe can form sharp splinters. Choose protective equipment and handling practices based on the current safety documentation for the specific resin, cloth, and other materials you use; do not treat the precautions in a 2015 project account as a substitute for those instructions.
Quick Recap
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