With the action lowered as much as I did, the fingerboard defects became apparent. My Elan is over 25 years old and had some grooving under the strings, especially those most frequently used spots: A string 3, 5, & 7th positions. Instead of a nice sound, it was a little more like a fart sound. Not good.
I have a tech friend that does really good setups, and I checked on him sanding / resurfacing my fingerboard. But he is also a CPA and it's tax season. And he has a bunch of tech work stacked. So, he let me borrow his Stew-Mac 10-in. radius sanding beam. This is a really cool tool but in a scary way.
http://www.stewmac.com/Luthier_Tools/Tools_by_Job/Leveling/Aluminum_Radius-sanding_Beam.html So I took off two tuners, the nut, and pulled the neck pickup. I also relaxed the truss rods and checked for levelness - looked good. Then I taped some thin cardboard pieces to the body and peghead and started slowly going back and forth. It became quite evident the wear on the fingerboard. The worn places were untouched by the sanding for quite a while, but I was going slow. Finally they started to disappear. When it was all the same color, I was quite relieved. I then changed my technique and added a little subtle fall-away to the fingerboard near the body. This was done by adding a few pieces of blue tape to the fingerboard near the 12th fret and removing 1/2 of the sandpaper from the sanding beam.
The paper used was a 240 grit. This was followed by progressively fine papers 400, 600, 800, 1000, & 1500. The board feels so smooth now. I also used a small block along the edges to knock off the now sharp edge.
One interesting finding: the fingerboard used to have an inlay? Can't really figure out what it was - but I'll look again later. It was probably removed, filled, and the wood stained black to cover it up. The wood is slightly lighter after sanding.
So, I put the pickup back in, removed the protective tape & cardboard, put the nut and tuners back on (with the 0.35 shim that I had previously made) and cleaned her up.
The first notes sounded so cool! Even sounds all over the board. Most important of all - the D note on the A string. Perfect! And after all of this, I made some more shims. I actually have about 8 sizes now and am using the 0.025 one. I might try one a little lower, but she's ok for now. I also had to lower the bridge and adust the intonation a little.
First time out, it was just our singer and her playing guitar. The last song was not practiced before playing this past Sunday. Perfect! It sounded so cool. The fretless is back.
Ill post a few photos tonight if I remember.
Stephen