Skip to main content
Music Radar MusicRadar The No.1 website for musicians
  • Guitars
  • Amps
  • Pedals
  • Drums
  • Synths
  • Software
  • Pianos
  • Controllers
  • Recording
  • Buyer’s guides
  • Live
  • DJ
  • Advice
  • Acoustic
  • Bass
  • About Us
  • More
    • Reviews
Magazines
  • Computer Music
  • Electronic Musician
  • Future Music
  • Keyboard Magazine
  • Guitarist
  • Guitar Techniques
  • Total Guitar
  • Bass Player
More
  • Purdie on the Purdie shuffle
  • Type beats
  • 86000+ free music samples
  • How to make an AI cover song
  • Three-chord trick

When you purchase through links on our site, we may earn an affiliate commission. Here’s how it works.

  1. News

Gibson Memphis factory tour

By Mick Taylor
( Guitarist )
published 16 December 2013

We take a look at where the magic happens

Gibson Memphis factory tour
We take a look at where the magic happens

Gibson Memphis factory tour

Gibson is perhaps the most loved guitar brand of all time, remaining at the centre of guitar players’ dreams and popular music history since the 1930s.

Always innovating, often controversial, what may look like a giant, impenetrable corporation from the outside is in fact a collection of smaller specialities and subcultures, fuelled by a deeply passionate staff of artisans and craftspeople who, regardless of position or function, remain fiercely proud of what they do.

The company has grown confidently ever since the much-written-about management buyout of 1986, as has its need for production capacity. Its first specialist offshoot was Gibson Montana, which began building flat-top acoustics in 1989. Next came Gibson’s Custom Shop in a separate Nashville facility in 1994, and today we’re visiting the most recent ‘new’ factory, around 200 miles away in Memphis, where Gibson guitars have been rolling off the line since 2000. 2013 is significant, however, because it is the year Gibson Memphis has officially become its own division.

Page 1 of 22
Page 1 of 22
Meet David Winters...
The man who manages the magic

Meet David Winters...

David Winters has been with Gibson ever since 1986 and today he is general manager of the Memphis facility.

“We do all the guitars here with f-holes that wouldn’t be a carved top, like an L-5 or Super 400,” he says as we begin filling in some background.

“We built the facility from the ground up and we focus primarily on the ES-335s, 175s, 330s, 339s... anything with a laminate, semi- hollow body, including Lucille!”

Page 2 of 22
Page 2 of 22
Workin' in Memphis
Look at them, just waiting to be finished...

Workin' in Memphis

It’s fitting BB King’s guitar is made here...

“Memphis is really the crossroads for the blues. Clarksdale, Mississippi is just south of here, the Blues Highway is [South] 3rd Street that runs right through the city, and we’re just a block off Beale Street – what better location to be for blues and jazz?

"We’re so close to Nashville [Gibson’s HQ], yet they’re two completely different cities with two completely different cultures.”

Page 3 of 22
Page 3 of 22
Making the tops
"ES guitars use a three-ply laminate. The face is around one 60th of an inch, then the middle is poplar or basswood, and the grain runs in the opposite direction. Then there's the bottom maple sheet, and that's how it's laid up," says Gibson Memphis R&D and product development manager Mike Voltz

Making the tops

Some ES guitars are still built in the Custom Shop in Nashville, though, right?

“Yeah, when they were originally doing the [Historic Series ES-335] ’59 and the ’63 there, this facility was so much younger that we didn’t really have the expertise to do a true, true historically correct instrument.

"Over the past several years, however, we’ve really focused in on the details and now we’re capable of building those historically correct ES-style instruments.”

Page 4 of 22
Page 4 of 22
Pressing laminates
"It's not just a press," enthuses Voltz. "They bought that machine in the 1930s - a great big leaky piece of crap, but we love it. Grant Green with his 330, Joe Pass with his 175, this is the machine..."

Pressing laminates

How many people work here in Memphis?

“81 directly, then we have a peripheral staff of about 12 – support staff in things like engineering, buyers, schedulers, accounts, shipping... things like that.”

And how many guitars do you make here?

“65 a day, that’s up around 25 a day from where we were at the beginning of the year.”

Page 5 of 22
Page 5 of 22
Back plate
The three-ply laminates are pressed, glued and contoured.

Back plate

There’s so much hand work happening in production. How do you maintain quality control with such a high level of individual human judgement in so many areas?

“We have inspectors throughout, but before that, at those critical workstations we have examples of what each part should be.

"We try to achieve that consistency both through continuous training and also continuous monitoring. A lot of it still ends up in the hands of the operator paying attention and being trained properly.”

Page 6 of 22
Page 6 of 22
Rims galore
The rims begin 12 inches wide, also three- piece laminates. They're bent on a machine and then cut to the correct body depth.

Rims galore

If we take just one aspect – let’s say scraping the binding back after finishing – how long does it take to train someone to do that?

“Oh, it can take anywhere from one to three months for somebody to become proficient at it. Some people pick it up quicker, obviously, but it is a very detail-oriented job that takes finesse. The only gauge is a visual gauge – it’s totally hand-done.”

Page 7 of 22
Page 7 of 22
Attaching centre blocks
Where it's relevant to do so (such as in an ES-335, for example) a centre block is attached to the rims.

Attaching centre blocks

Presumably some areas lend themselves better to mechanisation?

“Over the years we’ve developed tools for different areas. Sometimes it works and sometimes it doesn’t, because sometimes there’s just no better way [than hand work]. But a prime example is that for quite a number of years, fret-levelling was always done by hand, until the invention of the Plek machine.

"Now that does a complete scan of the neck and comes in and looks for detailed inconsistencies: a piece of equipment that does a great job. It’s a quality enhancer – a guitar that’s been Plek’d plays better than one that hasn’t.

Page 8 of 22
Page 8 of 22
Adding tops and bottoms
Tops and backs are joined to the rims using glued-in kerfing (similar to flat-top acoustics). What you end up with is a body 'sandwich' that's ready for shaping.

Adding tops and bottoms

“But a lot of it just has to be done by hand: cutting the binding back, rolling the binding in...

"Y’know when somebody picks up a guitar, the first thing they do is they put it in the playing position and they feel the neck. They run their hand up that neck; getting that feel right has to be done by hand.”

Page 9 of 22
Page 9 of 22
Binding channels
Binding channels are cut on a machine...

Binding channels

Has Gibson always made its own laminates for ES-style bodies?

“Each model has its own spec and shape, the important thing is having all three pieces of wood [for the laminate] with identical temperature and moisture content.

"So we bring the wood in and we let it equalise, because when you glue those three pieces together, they have to be pretty exact as far as humidity and moisture content are concerned."

Page 10 of 22
Page 10 of 22
Wrapping the binding
...ready for the incredibly physical and laborious process of gluing and wrapping the body binding into place.

Wrapping the binding

"So it equalises the wood at the same time when you heat it and cool it like that with the glue; it helps it hold its shape. We can control the quality by doing that in-house.

"You can see the original press in the factory. It’s from the early 1940s, we think. It’s pressed nearly every laminate guitar Gibson has done since the 1940s: a pretty remarkable piece of equipment.”

Page 11 of 22
Page 11 of 22
Bound for glory
Here's a bunch of lovingly binded guitars bound up tight

Bound for glory

With the explosion of knowledge online – whether it’s correct or not – you guys are under more pressure than ever to get those tiny details right. Do you feel that?

“Yeah! The internet has been a good and a bad thing. It’s provided a lot of knowledge to a lot of people who otherwise wouldn’t be exposed to it. And not only with guitars, of course: everything.

Page 12 of 22
Page 12 of 22
Neck pocket routing
CNC machines cut precisely positioned routs for the neck pocket, pickup recesses, bridge stud holes, f-holes, pot positions and so on, albeit not all at the same time.

Neck pocket routing

"At the same time, it’s allowed people with bad information to have a voice, so there’s a lot of misinformation out there as well.

“When you actually look at guitars from the 1950s and earlier, there was quite a bit of variation. Back then there was even more hand work done to the guitars, so it was even harder to control."

Page 13 of 22
Page 13 of 22
Neck adjustments
Once the neck is CNC cut and approximately shaped, truss rods are installed and the neck adjusted to an optimum position before it's flattened off ready for its fingerboard.

Neck adjustments

"There were not only a lot of inconsistencies from a materials standpoint, but also from a dimensional and workmanship standpoint.

"There were some beautiful guitars made back in those days, and those are the ones we try to emulate. A lot of those guitars have what we like to call the ‘mojo’ – tone, feel, history – they really push us to keep getting better and achieve that mixture of wood and paint and lacquer and electronics and hardware for that optimal tone.”

Page 14 of 22
Page 14 of 22
Shaping the neck
Necks are then further shaped and profiled by hand. There's a whole manual binding operation here, too: channels cut, binding cut, glued-in and shaped - again, all by hand.

Shaping the neck

Do you use any modern methods for examining old guitars?

“Recreating those instruments is quite the undertaking, so yeah, one example is this gentleman by the name of David Carpenter out in Washington State who not only has a collection of great guitars, but who also has friends in the medical industry.

"They’ve taken guitars and put them in MRI machines to measure densities of materials... all kinds of exact measurements. So he’d take his original guitars to his doctor, and the next day I’d get an email...

Page 15 of 22
Page 15 of 22
Hand sanding
There's a great deal of hand-sanding at every stage. "There is not one flat spot on an ES guitar," confirms Voltz. "It's all radius'd. It takes a lot of practice and a tremendous amount of skill."

Hand sanding

“We’ve found some interesting things; that’s where you find a lot of the variances in the guitars over the years.

"For example, we found original ’59 335s that had head and tail blocks on the centre block, which you rarely see. Most of ’em we’ve seen have been single pieces.

"You find those nuances. It’s a guessing game. If you look at the original blueprints, it called for a solid centre block, but maybe they had limited materials available to ’em, so they made what they made out of necessity.”

Page 16 of 22
Page 16 of 22
Finishing
Basic construction and sanding completed, the guitar goes off for sealing and finishing, itself a laborious, multi-stage, nitro-cellulose lacquer process.

Finishing

Will other guitars ever be made here?

“There are no immediate plans to move other guitar production to Memphis. There’s always the goal every year to design new models and/or recreate ‘new’ old models – like the ES-330s and the 295 we’re doing this year – or we make adjustments to current models.

As we get feedback from dealers and consumers we’re finding out what people prefer. We value feedback from experts, dealers and, of course, consumers because those are the people who fork over money. But the true gauge is what sells, and that’s where we try to focus.”

Page 17 of 22
Page 17 of 22
Scraping the binding
Once finished, all the binding is hand- scraped back. This is done freehand on every guitar, requiring immense skill (demonstrated here by Terry Boyd).

Scraping the binding

How do you approach the development of a new model?

“We always shoot for new, innovative product. The ES-139 and the 195 this year, they have some features you might find on historical guitars, but as an example the 390 over there [points to a new, small-bodied single-cutaway thinline with no f-holes], that was based off of the ES-330, being hollow, but you never know what it’s going to do when you shrink body sizes and make changes to hardware and pickups: it’s purely experimental.

"When we build prototypes, we’ll run them past some people to get feedback out in the market; we can’t just put Gibson on the headstock of anything and expect it to sell. The guitar market is competitive, so being innovative and coming up with new products is a prerequisite for each division every year.”

Page 18 of 22
Page 18 of 22
Buffed to a finish
Finished, scraped, Plek'd and fettled yet more by hand, the guitar is then buffed, either to go on for VOS treatment, or into final assembly for parts and strings.

Buffed to a finish

Gibson is often criticised for some new products – the Firebird X is a good example – being ‘too innovative’ or ‘out there’, but it’s always been that way, hasn’t it?

“The Flying V and Explorer? Those were pretty radical shapes back in the 1950s. They didn’t sell real well back then, but they’re now staples in the guitar industry. They were the Firebird X of their time.

"Yes, you catch some grief about it, especially from the purists, but the innovative guys understand what we’re trying to achieve. We stay focused and do what Gibson has done best for years, but we also have to lead. If we don’t, somebody else will!”

Page 19 of 22
Page 19 of 22
VOS process
Gibson's aged-but-not-aged process explained

VOS process

Many of us like our guitars to exhibit the time-earned elegance of a vintage original, but tend to wince a bit at serious wear and scratches on a new instrument.

Gibson’s VOS process is exactly that: a fully finished guitar made to look ‘old’ with a special combination of finish and hardware treatment. Approximately 30 per cent of Memphis-made guitars are VOS.

“We have a lot going through,” explains Mike Voltz. “They’re very popular in the market right now: through the roof!”

Rather than physically chip and ding the guitar, Gibson instead opts to dull the nitro- cellulose finish back just slightly, while also tarnishing the various hardware and other components, using a series of closely guarded techniques, materials and chemical treatments.

“The idea is that maybe the guitar got played for about three months or so,” continues Jim Lillard, manager of final assembly, repair and VOS hardware processes. “Then it went back in the case, [got] put under the bed and forgot about. During that time, the lacquer – solvents – will evaporate inside the case that produces a kind of haze.

Page 20 of 22
Page 20 of 22
VOS fittings
Rusting it up right

VOS fittings

“Tailpieces, tuning gears, bridges, and various other metal parts are aged in acid,” continues Lillard. “We get the effect that parts would have from oxidising naturally.

“On a Bigsby we also have to scrape the black paint off the patent number. The way they come now, the only thing that’s exposed is the ‘Bigsby’ part: it all takes time and extra attention.

“The other parts, we have to rust: pickup polepiece screws, strap buttons, screws...”

Lillard goes on to explain how Gibson’s ageing processes need constant refinement. “[Parts] manufacturers are trying all the time to frustrate what we do with the ageing,” he laughs. “Nobody wants to see their products all tarnished and aged; they want it to look shiny as long as possible!

"Like these [new] strap buttons. They’ve switched something so they don’t age as well, so I need to come up with some new tricks!

“As for the plastic parts, the knobs are wiped with an oil to give it that finger-funk kinda feel: we do it all right here.”

Page 21 of 22
Page 21 of 22
And it's done...
Here's the gold standard: an all original 1959 Gibson ES-225T, '57 ES-175 and '59 ES-330

And it's done...

Gibson Memphis is turning out some amazing guitars in the best traditions of the brand, and if you're a sucker for an elegant semi-acoustic then you're no doubt GAS-ing pretty hard right now.

To check out the guitars currently coming out of Memphis, check out the official Gibson website.

Page 22 of 22
Page 22 of 22
Mick Taylor
Social Links Navigation
Editor-in-chief, Guitars Group
More about guitars
Wampler Tweed '57 and Black '65

Wampler brings back its Fender-inspired Tweed ’57 and Black ’65 amp-in-a-box drive pedals – for a limited time only

Laney Ironheart Foundry DualTop

“All the ferocious growl and bite of an Ironheart you know and love”: Laney adds two compact, affordable and feature-stacked 60W amps to the Ironheart Foundry series

Latest
Nirvana In Utero cover

Nirvana session cellist Kera Schaley talks about playing on In Utero: "The funny thing about All Apologies is Steve kept trying to talk Kurt out of putting cello on it"

See more latest ►
Most Popular
“It makes it exciting and dangerous and fun”: Yngwie Malmsteen says he doesn’t need to rehearse anymore and explains why he mostly ignores the setlist

By Jonathan Horsley22 September 2023

9 tips for buying second-hand music gear without getting scammed

By Andy Jones22 September 2023

Pro Tools Sketch: industry-standard DAW gets Ableton Live-style clip launching and a free iPad app, but will it convince you to switch?

By Si Truss22 September 2023

Elon Musk allegedly turned up at the studio with a gun while Grimes was recording dialogue for Cyberpunk 2077: "The studio guys were sweating"

By Matt Mullen22 September 2023

Electro Harmonix unveils the 9 mini Pico effects pedals for its NYC DSP Series – with reworked old favourites and new designs

By Rob Laing21 September 2023

DAW not doing it for you? Cantor is a free “music playground” for looping, sampling and sound design

By Ben Rogerson21 September 2023

Watch bluegrass guitarist Ian Ly become the 2023 US National Flat-picking Champion

By Rob Laing21 September 2023

Audiomovers launches Off The Record interview series with first episode featuring Dire Straits producer Chuck Ainlay

By Matt Mullen21 September 2023

“I thought, ‘have I done something heinous?’”: James Blake reminds Brian Eno that he once accused him of using ‘the arsehole chord’ and demands to know what it actually is

By Ben Rogerson21 September 2023

The Vai, Bonamassa, Di Meola and Abasi-backed guitar virtuoso Matteo Mancuso dazzles again on new song Silk Road

By Rob Laing21 September 2023

DAACI is the AI-powered 'meta-composition' software that writes music like a human: "It's interpreting what comes from a composer’s brain, rather than trying to imitate something that’s already been made"

By Andy Price21 September 2023

  1. Marty Friedman
    1
    Marty Friedman’s guitar teacher told him to take a bong hit every time he played an exercise correctly, but the ex-Megadeth guitarist has better advice for students
  2. 2
    "It's become so elitist" – Joe Bonamassa weighs in on players being priced out of the vintage guitar and amp market
  3. 3
    “Right now I’d like to do a song, it’s a little thing by Howlin’ Wolf…”: Listen to Jimi Hendrix’s newly unearthed performance of Killing Floor at the Hollywood Bowl, 1967
  4. 4
    The Vai, Bonamassa, Di Meola and Abasi-backed guitar virtuoso Matteo Mancuso dazzles again on new song Silk Road
  5. 5
    Watch bluegrass guitarist Ian Ly become the 2023 US National Flat-picking Champion
  1. Cindy Blackman Santana
    1
    Cindy Blackman Santana tackles the iconic In The Air Tonight drum fill as she joins Chris Stapleton and Snoop Dogg on a new version of the song for ESPN’s Monday Night Football
  2. 2
    Watch bluegrass guitarist Ian Ly become the 2023 US National Flat-picking Champion
  3. 3
    “It makes it exciting and dangerous and fun”: Yngwie Malmsteen says he doesn’t need to rehearse anymore and explains why he mostly ignores the setlist
  4. 4
    Elon Musk allegedly turned up at the studio with a gun while Grimes was recording dialogue for Cyberpunk 2077: "The studio guys were sweating"
  5. 5
    “When it came in as a demo, I assumed the rest of the song was going to be built out”: Kylie Minogue didn't realise Padam Padam was finished when she first heard it

MusicRadar is part of Future plc, an international media group and leading digital publisher. Visit our corporate site.

  • About Us
  • Contact Future's experts
  • Terms and conditions
  • Privacy policy
  • Cookies policy
  • Accessibility Statement
  • Careers

© Future Publishing Limited Quay House, The Ambury, Bath BA1 1UA. All rights reserved. England and Wales company registration number 2008885.