Brian May Red Special Guitar: Jeanrenaud Switch Full Replication

Brian May Red Special Guitar: Jeanrenaud Switch Full Replication
In this video, I take you through all the processes and techniques required to replicate the highly sought after and extremely rare and hard to find vintage Jeanrenaud DPDT (double pole double throw) parallel slide switches of the same type fitted to Brian May’s Red Special guitar.
In 2019, I collaborated with Andrew Guyton of Guyton Guitars and Tim Grocott to produce replicas of these switches for his limited edition run of high end, super authentic Time Warp Red Special guitars. These guitars were born out of demand created by the prop guitar he made for the movie Bohemian Rhapsody about Freddie Mercury’s time in Queen.
Firstly, I discuss why these switches are key to maintaining the correct aesthetic appearance of the iconic Red Special guitar.
I disassemble a vintage donor switch provided by Manuel Angelini of DoxyWorld.com in Nantes, France and use the information to design the replica Tufnol wafer, metal chassis, plastic actuator, steel detent wire and brass sliding contacts in CAD.
I CNC cut the wafers from Tufnol phenolic resin sheet thicknessed to 1.6 mm. I also CNC cut the brass sliders from 0.35 mm brass sheet and the metal chassis from 0.8 mm thick 5052 grade aluminium sheet.
I use 3D SLA (stereolithography) resin printing with an ELEGOO Mars 4 DLP printer and Phrozen brand ABS-like “creamy white” 3D printing resin to recreate the plastic actuators.
Please check out the collaborate section of my website for further details on this intricate and challenging build project.
Thanks to fellow Brian May Red Special enthusiast, Julian Hemingway for providing information on his Jeanrenaud switch, helpful discussions and ideas and for evaluating my components.
Video Chapter Time Indexes
00:00 - Introduction.
00:35 - Montage of thumbnails of my other KZbin videos.
01:05 - Examination of the exterior detail of a vintage Jeanrenaud DPDT parallel slide switch.
01:31 - Brief history of the Jeanrenaud company started by Swiss Henri Jeanrenaud in Dole, France.
02:05 - Looking under the hood of my home made Brian May Red Special guitar.
02:32 - Why the Jeanrenaud switch is key to achieving the correct aesthetic appearance of the original Red Special.
03:13 - The Guyton Time Warp Red Special replicas.
03:44 - Disassembly of a vintage Jeanrenaud switch.
04:35 - Examination of the internal components of a vintage Jeanrenaud switch.
05:36 - 3D CAD representation of the component parts of a vintage Jeanrenaud switch.
06:12 - 3D FDM (Fusion Deposition Modelling) printing; the Prusa i3 MK3S+.
07:25 - 3D SLA (stereolithography) printing; the ELEGOO Mars 4 DLP printer.
08:21 - CNC milling the Tufnol phenolic resin wafers.
08:50 - CNC thicknessing the Tufnol phenolic resin wafers.
09:20 - CNC milling the metal chassis from 0.8 mm thick 5052 aluminium sheet.
09:54 - CNC milling the sliding contacts from 0.35 mm thick brass sheet.
10:19 - Preparing the 3D printer files for the plastic actuators in Lychee Slicer software.
11:29 - Batch of twelve actuators emerging from the 3D printer’s resin VAT.
11:38 - Examining a batch of twelve actuators after initial clean-up and before curing.
12:02 - Scraping the uncured actuators off the 3D printer’s build plate.
12:22 - Removing the bases and supports and cleaning with isopropyl alcohol.
12:45 - Curing the 3D printed actuators with a UV nail gel curing lamp.
13:39 - Examining Jeanrenaud brand vintage rotary multipole switches.
14:02 - Salvaging contacts from rotary switch wafers.
14:30 - Discussing the function of the detent wire.
15:08 - The custom detent wire bending jig (Delrin plastic).
15:29 - Manually forming the detent wire using the Delrin bending jig.
16:02 - Comparing the formed detent wire with the original component.
16:24 - Folding the aluminium chassis using a StewMac fret arbor press and a custom Delrin jig.
18:09 - Riveting the salvaged tinned copper contacts to the wafers using Keystone No. 24 wide roll PCB eyelets and a mini die and punch kit.
18:59 - Folding the brass sliders mounting tabs using a precision engineering bench vise.
19:23 - Inserting the brass sliders into the actuator bases by thermosetting.
19:43 - Reviewing the actuator sub-assembly.
19:56 - Inserting the detent wire.
20:02 - Sliding the actuator into the static contacts.
20:15 - Placing the metal chassis on top.
20:21 - Bending the mounting tabs on the metal chassis over.
20:47 - Outro 1: pictures of the set of six finished switches.
20:58 - Outro 2.
#Jeanrenaud #BrianMay #RedSpecial

[@dsgb]

I have uploaded watermarked 3D CAD files for each component to Thingiverse: www.thingiverse.com/dsguitarblog/designs

[@TheRedSpecialGuitarPodcast]

Wow what dedication and what a fantastic looking switch at the end of it. Always in AWE of your work Doug! Thanks for doing these videos.

[@dsgb]

Thank you so much brother Underhill. 💜🙏🏻😀

[@nicbahn]

I just love your attention to detail. You really have to be a bit insane but to go the extra mile and analyze, redesign and machine these parts is really fun and so damn satisfying. Thanks for sharing and man, the machines you got, what a dream for tinkerers haha

[@dsgb]

Thank you so much for your supportive comments and I'm pleased that you liked watching this video. 🙏🏻💜 A lot of my motivation arises from trying to learn new skills and improve existing ones which includes video production of course. However, the unfortunate reality for many niche enthusiast communities (particularly automotive and vintage audio) is that some people have to take on reverse engineering, designing and small volume manufacturing obsolete components or existing parts with original design compromises or flaws. Regards. Doug

[@watsonstudios]

Great video! Yeah, I went through that process of making switches and it was rewarding, but man, it was a lot of work! To bend my wires, I made a 3d resin printed 2 part form that I used to press the wire into the proper shape.

[@dsgb]

Thanks! 🙏🏻 I considered the method you used.

[@ianbuxton525]

A beautiful piece of reverse and forward engineering. Extremely well done. Thank you for sharing. I would like 3 sets please if you make some more.

[@dsgb]

Thanks Ian. I might make one or two sets for sale to use up some spare components but this is unlikely. Dansan Guitars sells very good replica sets: dansanguitars.com/store/

[@palacraft8916]

Amazing Work and Video ! Very Beautiful Switches

[@dsgb]

Merci beaucoup Nolhan. 🙏🏻💜

[@nicolasfrom]

Crazy amount of work doing these videos! Thanks!

[@dsgb]

It's gruelling but the end result is always worth the effort. I'm happy that you appreciate the work involved. 👍🏻💜😀

[@paulwomack5866]

Wonderfully entertaining as an exercise in perfect authenticity. Although anyone wanting Red Special wiring could simply use any compatible (but not historically identical) switch!

[@dsgb]

Thank you Paul. I'm pleased that you found the video entertaining. 🙏🏻💜😀 The best option for Brian May Red Special switching are the push-to-make, push-to-break microswitches on a PCB used in the Guyton RS Transporter and on my converted Fender Stratocaster. Check it out if you haven't seen it already.

[@zapp442]

This is simply amazing. Thank you so much for sharing. You are amazing!

[@dsgb]

Thanks for your feedback and kind words. 👍🏻💜😀

[@RedSpecialTribute]

Amazing video Doug! Very informative! I’m glad to have a replica of these switches in my rs :)

[@dsgb]

Excellent! Which versions do you have installed? 😀

[@RedSpecialTribute]

@@dsgb I have Dansan’s Replica of the switches :)

[@jemwand2530]

" You went full Geek. Don't ever go full Geek man, that's career suicide."

[@dsgb]

😂 Whatever 'career' I might have had is pretty much done in any case.

[@gplaza]

Amazing as usual!

[@dsgb]

Thanks Gonzalo. 🙏🏻💜😀

[@itsdgo3066]

Another fantastic video great work😊

[@dsgb]

Thanks for your kind comments. 👍🏻😀

[@colinhumphrey7833]

Just amazing !!!

[@dsgb]

Thanks Colin. 💜🙏🏻 The Jeanrenaud switch reverse engineering and remake project was one of the most challenging projects I have taken on.

[@ThomasBrunkard]

Those are the same switches that have been in the guitar from the start? Wow!

[@dsgb]

Yes. Manuel told me he provided a set of original switches to Brian for spare parts. Not required so far...

[@tiberiolincoln5687]

Amazing..... Congatulations, Very good 👏👏👏👏👏

[@dsgb]

Thank you very much. 😀

[@warrymoss9735]

Thx for the video, it's really informative! Will there be a similar video about the bulgin jack socket in the plans? It would be great to make the necessary electronics yourself instead of looking for it on ebay or waiting for it to appear there... I apologize if I do not understand some aspects related to electronics. Thanks in advance for the answer! :)

[@dsgb]

Hi. I'm pleased that you found this video informative. I have considered making a video about replicating a DIY Bulgin jack socket for the reasons you state but I decided against it because it will require metal sheet to be cut and bent into a specific uniform shape and riveted. It is not important to maintain cosmetic or engineering authenticity on a Red Special replica either. This would be too much effort and I don't think woud result in an interesting video. Especially when a long barrel Switchcraft 1/4" jack socket is fit for the purpose, easy and cheap to source.

[@marinedalek]

It seems like it should be possible to photo-etch the brass sliding contacts, and probably also the static contacts. Folding the latter would be another question, of course...

[@dsgb]

Possibly. I am not familiar with photo-etching. I thought it is intended for very thin copper layers on printed circuit boards, not relatively thick sheet metal. 🤔 Coincidentally, I was just watching an interesting video on photo-etching PCBs using a 3D SLA printer: kzbin.info/www/bejne/iKbHhKeYiKajmqc

[@marinedalek]

@@dsgb it’s commonly used for etching small brass parts for scale models, especially railway modelling. I had a brief look earlier and there were some online services where you can upload your own artwork and they etch the parts.

[@CrossGuitarWorks]

Doug! Chapeux 💪 you are a fkn genius. Hioe to meet you atbthe meetmup this year

[@dsgb]

Thanks! I'll be there and it will be great to finally meet you. 🤘🏻

[@CrossGuitarWorks]

@@dsgb that's great. It shall be my first time. Been telling myself maybe 8yrs I should go but besides travelling and expense, it coincides with my other half's birthday. This year I am slipping away and shall pay the price eventually surely 😅

[@dsgb]

You will be made to feel very welcome and will find yourself among many kindred spirits. Prepare to geek out RS brother! 😬

[@fabmay1985]

Hi, do you can make a set of this Jean r. With a white tip like a switchcraft switch? Because I've my pickguard with a switch craft hole... 😢

[@dsgb]

One of the main motivations for making replica vintage Jeanrenaud switches is for the smaller sized actuator. If you want to fit these, you would need to make a new pickguard to match. It would be possible to design and make a Jeanrenaud style switch with a modern Switchcraft sized actuator tip but surely this would be somewhat pointless?

[@rubikill3684]

Una pregunta buenas , se pueden comprar los interruptores en otras partes ? Me refiero en tiendas donde venda interruptores , e visto interruptores similares a las de ustedes o buena tambien de diferentes formas , sera que influye en el sonido ?

[@dsgb]

Unless you can find stores which sell NOS (new old stock) or recovered vintage electronics equipment, the original Jeanrenaud switches fitted to the Red Special are extremely difficult to find retail. As is the way in a capitalist society, people who trade in vintage audio and vintage electronics can research items that are in demand by niche enthusiast groups and charge high prices for what were originally low cost components. This is why it is more satisfying to make your own. You can use any suitable panel mounted DPDT switch. Toggle switches are popular for example. The push-to-make push-to-break PCB mounted microswitches on the Guyton RS Transporter that I used on my Stratocaster conversion are very intuitive: dsgb.net/projects/maycaster/part8/ Different switches will not influence the sound but should always be make-before-break to avoid generating circuit noise during actuation. Although modern Tri-Sonic pickups are potted to reduce microphonic feedback, they can still pick up mechanical actuation noise.

[@matthewapsey4869]

Do you build guitars for a fee?

[@dsgb]

You have previously asked me this in the comments section of another of my videos Matthew. The answer is still no. 👍🏻😀 I have updated my channel guidelines to reflect this. See also the answer to FAQ question 2 on my website: dsgb.net/faqs/