McCarty 549 Follow-Up - 1950’s Manufacturing Was Always A Bit Dodgy

The tone pots on my Epiphone Les Paul were monsters, especially on the bridge. Turn the bridge tone pot up to 10 and the sound was 10dB (!) louder than at 0. Neck wasn’t quite as much, but it was still unmistakeable. And to my ears the difference in tone was independent of the volume pot setting.

The effect of the McCarty tone pots depends on the volume level: the higher the volume pot, the greater the difference between 0 and 10. The difference is greater at the bridge than the neck, but that’s because physics.

Which is one reason it took me a while to notice that the bridge tone pot wasn’t actually working. Coil split was, but not the tone control. The neck one was okay.

So back to those nice people at GuitarGuitar Epsom I went, where their wonderful tech swiftly diagnosed a dry solder joint. A quick touch of the iron, and everything worked as it should. All covered by warranty.

A lot of a modern guitar is made by CNC tools. The body is cut by CNC millers, which is why the body shape is so consistent. The pick-ups are wound by a CNC winder, so every pickup gets 5,324 turns of 60AWG (or whatever) - as opposed to 1950’s Gibson pick-ups which were wound by hand and could vary considerably. The necks must be cut and fretted by machine as well, given the cost of a luthier re-fret these days.

The wiring has to be done by hand. I doubt even Apple could automate that. The connections are soldered by hand. Just like when Leo Fender made his first guitar for Noah on the Ark. Hand-soldering has not improved since it was invented. The mid-teenage me used to solder slot-car chassis back in the day, and even I could get a dry joint now and again. However, I wasn’t making lots of chassis in a day, so I had time to spot it and re-solder. The guys in the factory probably don’t have the time.

Once upon a time, cars used to be assembled more or less by hand, and we could tell. Rattles, squeaks, screws coming loose… There’s a reason Ford, Fiat and the rest spend gajillions developing automated manufacturing. It’s the reason that modern cars are so reliable and last so long. That and improved paint formulations.

Guitar-makers don’t work at the volumes of car manufacturers and can’t afford the investment in specialised robots. So we will just have to accept that, at least for the budget-price market (if PRS SE prices are your idea of “budget”), a fair proportion of the guitars will need some post-sale tweaking to get 100% right.

Now everything is copacetic. The default volume pot setting is around 7-8, which lets the tone pots do their thing. I had to tweak some settings on my HX Effects, but I’m getting real slick at playing the stomp switches.

My McCarty 549 SE sounds great, has humbuckers, the Les Paul control layout, and weighs 7 lbs. It’s not going anywhere for a long time.