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apetaster · 05-03-2003, 03:34 AM

The way I would do it:

I would make a template of the exact patterns you want to cut out of thin stock (I like hardboard, which can be found cheap at yards and home centers.) The template can be attached to the body using double stick tape. Use a (3/8" at least) straight cutting bit in conjunction with a router collar, which will effectively 'follow' the pattern. Note that the template will need be slightly larger than the desired holes b/c of the extra diameter the collar needs.

Plan on making many passes, especially if your router is less than 3HP, and/or if you are using a 1/4" shank bit. DO NOT rush the cut and and make shallow cuts in each pass. I had a thin fluted bit snap in half on me while running and flew right by me at sac level - that carbide could have been the end of an important part of me. If you have a need for square corners (which you really don't since all cavities are hidden, except possibly the neck/body junction) you'll have to chisel.

Out of curiosity, what are you making the body out of, and are you making your own neck (hard!)

05-03-2003, 03:34 AM	#3 (permalink)
apetaster Insane Location: P.R. Mass.	The way I would do it: I would make a template of the exact patterns you want to cut out of thin stock (I like hardboard, which can be found cheap at yards and home centers.) The template can be attached to the body using double stick tape. Use a (3/8" at least) straight cutting bit in conjunction with a router collar, which will effectively 'follow' the pattern. Note that the template will need be slightly larger than the desired holes b/c of the extra diameter the collar needs. Plan on making many passes, especially if your router is less than 3HP, and/or if you are using a 1/4" shank bit. DO NOT rush the cut and and make shallow cuts in each pass. I had a thin fluted bit snap in half on me while running and flew right by me at sac level - that carbide could have been the end of an important part of me. If you have a need for square corners (which you really don't since all cavities are hidden, except possibly the neck/body junction) you'll have to chisel. Out of curiosity, what are you making the body out of, and are you making your own neck (hard!)