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Hey guys, I need some help making the control cavity cover out of the same piece of wood as the back. I would like to hear the different methods you use for cutting out the cover. Also, those of you that use magnets to hold on the cover, how are they set up? Thanks.

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Chris

Hey,

I use two methods, only one which is worth anything...

0. if you have access, have it laser or waterjet cut...I don't
1. Cut it out on a scroll saw with a very narrow blade...this seldom looks good.
2. Use a Dremel with its circular router base attachment. Make an offset template that 1/2 the diameter of the router base larger in all dimensions than the control cavity outline. Insert as narrow a bit as possible (i use a 1/16th two flute down cut endmill bit because the 1/32 simply break too often). Very slowly, and in one pass if possible, make the cut. Depending on the thickness of your laminate, you may have to finish the cut with something like a scroll saw (with a blade narrower than the endmill), but this approach will give you something very clean to start with.

The router bit approach only works with back veneers that are less than about 0.375"...anything thicker, then, well, I would recommend not doing it at all becase it is very difficult to get something that looks professional. In these cases, I simply use offcuts from the body and do my best to match the grain. If I canot, I make it very apparent that I am not trying to match the grain and run it at a good 45 degrees or so off...

Stephen

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www.ziegenfussguitars.com

Thanks Stephen. I tried using a Dremel and just was not happy with it. I may have to change my template following method or maybe set it up something like a pin router.

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Chris