I measured at least 10 times before making the cavity cuts. These need to be done before shaping so there is support for the tools – drill press and router.
Before beginning the routs I had a little cleanup to do on the butt end of the through neck. The photo shows I back cut the tuner mount (this travel guitar is headless and has the tuner behind the bridge) to 20 degrees. This is so the tuners swing nominally level after tensioning the strings. If I didn’t do this the tuners would stick up in an ugly way. In a later post I’ll show how the tuners work.
Back Cut Base of Neck 20 degrees for Tuner Mount
So then we move on to the routs.
First I cut the control cavities. The location of these is not critical to guitar sound. This was done by first drilling through holes at the diameters of the controls (two potentiometers 3/8” and a switch 1/2”). I added some spotfaces so the knobs will look clean when installed. Then I flipped the body over and hogged out using a 1 1/2” Forstner bit. You can see in the photo this result with a pot dropped into the cavity to illustrate. The cavity was cleaned out with a chisel. Then I uses a 1 3/4” Forstner bit to cut the rabbet for the cavity cover, evening this out with chisels.
Through Holes with Spotfaces
Back Cavity with Pot Shown
Cut Cover – Smoothed with Files
Cover Shown Installed
Finally I cut the Humbucker routs. The location is important according to my resources – they need to be as near to the bridge and necks as possible.
Damn! Now’s taking shape, literally. Next I’ll use the sandpaper disk grinder to shape it all up… see you soon.
-- Dave, New England - “We are made to persist. that's how we find out who we are.” ― Tobias Wolff