Chicago's Premier PLEK Machine Guitar Setup at Third Coast Guitar and Amp Repair

Third Coast’s Chris Eudy explains the process behind personalized guitar setups and dispels some common misunderstandings of the PLEK process of fret leveling.  

By Chris McMahon, MSJ

While a PLEK fret level is a largely automated process, the PLEK operator has many opportunities to customize results to accommodate an individual guitar player's style and preferences. 

"It's not just about throwing the guitar in the machine and hitting 'Go,'" laughs Chris Eudy, owner of Third Coast Guitar and Amp Repair in Chicago. "You've got to really dig into what the player is looking for, what kind of music they're playing, and how they want their guitar to feel." 

It all begins with the right hand, he says. Whether you play with a plectrum, and what kind, are primary concerns when customizing a PLEK setup because your attack—how hard a player strums or picks the strings—impacts the optimal setup. 

A thicker, harder pick, for example, is going to dig into the strings more, which could cause some buzz if the guitar's action is set too low or the frets aren't leveled just right. On the flip side, if the player uses a thinner, more flexible pick or has a lighter touch, you can get away with a lower action without any issues. 

"It's all about finding that sweet spot, that perfect balance between playability and buzz-free performance," Eudy says. 

String and string-height preferences are next. "Are they rocking some heavy-gauge flatwounds or some light-as-a-feather plain strings? That's going to make a big difference in how you set up the action and the overall playability. You plug that info into the PLEK, and it starts to get a sense of what it's working with," Eudy explains. Some players like their action low and fast. Others prefer a little more height, especially if they're digging into the strings or playing some gnarly bends, all of which must be considered when the operator sets the target action in the PLEK software, he adds. 

The bridge and fretboard radius are next. In the guitar used for the demonstration, an Eastwood Airline H78, the fretboard radius measured 20" while the bridge had a 12" radius, forcing Eudy to get a bit more creative to make it all work together. 

"The PLEK's going to give you a roadmap of where each fret's at, but it's up to the operator to interpret that data and make the call on how much to take off and where. You might focus on the 'money frets,' where the player is spending most of their time. Or you might do a more even job across the board. It all depends on what the player's after," Eudy says.

PLEK FAQs: How to get the most from your custom PLEK guitar setup

A well-trained PLEK operator can customize the setup process to achieve the best possible results for individual guitarists and specific instruments. Here’s a list of considerations to be discussed with the player:

• Playing style and technique: To balance playability and buzz prevention and achieve the ideal setup, the operator considers the player's style, such as whether they are mostly finger pickers or strum with a heavy pick, for example. 

• String gauge and material: The PLEK operator must input the correct string details to ensure accurate measurements and adjustments.

• Desired action: The string height can be customized based on the player's preference and playing style. Lower action is often preferred for fast, easy playing, while higher action may be better for certain styles or to avoid fret buzz.

• Pickup height: Pickup height can also be a consideration when customizing a PLEK setup, as it affects the guitar's tone and the potential for string buzz.

• Fretboard and bridge radii: The PLEK machine measures the actual fretboard radius and compares it to the desired radius. In our example, the guitar's fretboard radius measured nearly 20", while the bridge radius was 12". The operator must decide how to reconcile this difference for optimal playability.

• Fret leveling and crowning: The PLEK machine scans each fret and recommends leveling and crowning adjustments down to 0.001 mm (1/1000 of a millimeter). The operator can customize these adjustments based on the player's preferences and the guitar's specific needs, such as focusing on certain areas of the fretboard that see more play.

• Nut and saddle adjustments: The PLEK machine can also determine the optimized nut and saddle heights for the desired action and playing feel. The operator may choose to make these adjustments based on the player's input and the guitar's overall setup.

Adding the Human Touch to a PLEK’d Guitar

After a guitar emerges from the PLEK machine, it's far from finished and the handwork is about to begin. The first step in Eudy's post-PLEK process is a thorough inspection. He examines the fretwork and nut, which was also cut by the PLEK machine, before touching them up by hand.

Eudy pays special attention to the nut, which the PLEK machine has cut to precise specifications, including adjustments to the height of the nut, as well as the angle and depth of the nut slots. "I'll clean this up, and burnish the nut slots a little bit. This fine-tuning ensures optimal string movement and tuning stability,” he explains.

“We don't want to change the level of the frets. We're looking to change the shape of them just slightly," Eudy says. He then polishes the frets with progressively finer grits and buffs them out. 

Next comes the fretboard conditioning. "Dr. Ducks AX wax: It's just my favorite because it lubricates. It penetrates and helps clean up that buffing compound," protecting the wood and enhancing the guitar's feel and appearance, he says.

The setup process continues with Third Coast’s proprietary string installation technique, which ensures consistency across all strings and allows for precise tuning. After stringing, Eudy performs a series of checks and adjustments, slightly tightening the hardware where necessary. He then goes through a careful string stretching process on both sides of the nut and bridge.

Intonation is his next focus, ensuring the guitar plays in tune across the entire fretboard. The final step is a thorough playtest. Eudy checks every fret and every string, ensuring that the guitar plays and sounds as it should. 

"That's what we're after here: a blending of craftsmanship with efficiency,” he says. "The PLEK's just a tool. While the PLEK machine provides unparalleled precision, it's the luthier's skill and experience that truly bring a guitar to life. We're still the brains behind the operation."

This comprehensive approach ensures that each guitar leaving Eudy's shop is set up precisely and imbued with the care and attention to detail that only a luthier can provide. It’s this combination of cutting-edge technology and time-honored craftsmanship that sets Third Coast Guitar and Amp Repair's work apart from other shops and keeps Chicago’s musicians coming back.

PLEK Machines: Differences between The PLEK Station vs. PLEK Station Pro Explained

PLEK machines come in several different models and can be used in various ways depending on your goal. Third Coast's PLEK Station model is all about individual customizations. “It's like having a master luthier in a machine,” Eudy says, ready to tweak and tune every aspect of your guitar's setup for a bespoke experience.

"You're going to use this one when you want to take a deep dive into a specific instrument and really dial it in for a player's unique needs and preferences," Eudy says.

On the other hand, the PLEK Station Pro is the workhorse that enables speed and consistency for higher volume manufacturing, Eudy says. "It's like a digital version of their master luthier's brain, making sure every guitar meets their exacting standards," Eudy says. “Every company programs its own secret recipe into the PLEK Station Pro for an optimized setup. 

"It's the difference between a tailor-made suit and a really, really nice off-the-rack number," Eudy says. "Both are going to look and feel great, but one's just a little more personal.”

Is PLEKing a Vintage Guitar a Good Idea?

When it comes to PLEKing vintage guitars, Eudy understands the hesitation some guitar players may feel, given their history and value. However, Eudy firmly believes that the PLEK process can significantly benefit even the most cherished vintage guitars without compromising their value or "mojo."

"A guitar's only a guitar when we make music with it," Eudy explains. "Otherwise, it's just a piece of wood and metal hanging on a wall," he says. Further, a carefully executed PLEK job can preserve and enhance a guitar's playability and, by extension, its value.

One advantage of the PLEK process over a traditional fret level is its hyper accuracy, which allows for minimal material removal, often much less than is possible in a manual fret job. This is a critical consideration, given that vintage frets are typically smaller than modern frets and typically more worn.

Eudy also stresses the importance of the technician's role in the process. "We're still the brains behind the operation," he says, adding that each guitar is treated individually at Third Coast Guitar, with respect for its unique characteristics and history.

To alleviate concerns, Eudy often suggests a stepped approach. "Let's start small," he proposes. "We can do a scan first and show you exactly what's going on with your guitar." This initial step allows owners to see the condition of their instrument in unprecedented detail before any work is done.

Ultimately, Eudy believes the PLEK process can breathe new life into vintage instruments while preserving their essence. "We're not trying to turn your '59 Les Paul into some modern shredder," he assures. "We're just making sure it plays and sounds as good as it did the day it left the factory, maybe even better."

By combining cutting-edge technology with traditional craftsmanship and a deep respect for vintage instruments, Eudy and his team aim to ensure that they continue to make music for generations to come. "Your vintage guitar deserves to be played, and play well. The PLEK can make that happen without sacrificing an ounce of its character or value," he says.

Common Misconceptions about the PLEK Process

Misconception 1: The PLEK machine uses lasers to scan and work on the guitar

The PLEK machine does not use lasers. It uses a high-precision sensor that runs an electrical current to create a detailed 3D map of the guitar's fretboard, strings, and other components.

Misconception 2: Fret leveling by a skilled human luthier is better

While a skilled luthier or technician can do a good job, the PLEK machine can level frets with an accuracy of up to 0.001 mm (1/1000 of a millimeter), which is far more precise than what any human can achieve by hand.

Misconception 3: The PLEK machine does all the work

The PLEK machine is a highly sophisticated tool, but the operator's skill and knowledge are crucial for optimal results. The operator must input the correct data, interpret the scans, and make informed decisions based on the guitar's unique characteristics and the player's preferences. Detailing and setup are then executed by hand.

Misconception 4: A PLEK setup only benefits highly technical guitarists

A PLEK setup can benefit guitarists of all genres and styles, as it helps optimize the guitar's playability, intonation, and overall performance. Whether you play metal, jazz, rock, blues, or any other style, a well-set-up instrument will be easier and more enjoyable to play.

Misconception 5: The PLEK machine can fix any guitar issue

Some problems, such as severe neck warping or damaged frets, may require additional repairs or even parts replacement before a PLEK setup can be performed.

Misconception 6: A PLEK setup is only worthwhile for expensive, high-end guitars

While the cost of a PLEK setup may be more easily cost-justified for expensive instruments, even mid-range guitars can benefit significantly from the process. Improved playability and performance can help players of all levels progress and enjoy playing more, regardless of the guitar's price point.

Why a Customized PLEK Fret Level is the Best Solution

Third Coast Guitar’s collaborative approach to a PLEK fret level ensures that the player's preferences and needs are at the forefront of the customization process, Eudy says, and the player’s input is integral to a successful setup.

"At the end of the day, it's about having a conversation with the player and really understanding what they're looking for. Then the operator uses all the tools in the PLEK toolkit to make it happen. It's not just about the machine. It's about the operator's know-how and their ability to translate the player's vision into a killer setup,” Eudy says. “That's what separates the pros from the ‘Joes.’ You know what I'm saying?" 

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