Make a pair of somethings so that once the dimensions of one part have been set, it's easy to use that to create the dimensions of the second part

The difficulty is in machining the repair block by hand even if you have template for it. Feeding something only a few centimetres is size past a cutter, even using an inverted router table, means getting your fingers very close and I really wouldn't suggest anybody tries this. I'll give it some more thought but it would be a low cost system, give that there isn't any assembly work involved, just a bit of CNC routing of the template and patches.

Made a patch to repair the top of this Strat too today. 

@boo

Looks good how did you make the patch

Good job @boo, you’ve been busy today!

Looks good how did you make the patch

@rocknroller912 I used a chunk of the off cut from the guitar blank. It’s 40mm thick so I drew the dimensions out on the wood and cut that much off. I then measured about 12mm for the thickness and resawed it on the bandsaw. I cleaned it up on my bench sander and used it to draw around to make the internal routing template. 

@boo

I think that’s a pretty sound method it looks a good repair. Thanks for sharing.

I used a chunk of the off cut from the guitar blank.

The guy sent you the offcut as well as the guitar?

Did he know that there was a problem with the body that was going to need fixing??

I used a chunk of the off cut from the guitar blank.

The guy sent you the offcut as well as the guitar?

Did he know that there was a problem with the body that was going to need fixing??

@tv101 No, sorry TV, my mistake. The offcut was from the Bandsman I’m building, I did a similar thing to cover the neck joint. Both guitars are Poplar though so at least it’s the same wood. Today I will get them both more or less flush with the tops and then glue them in, I’ll use some bamboo pins as well. Once that is set, I’ll fill in any gaps with epoxy. 

Hey @boo I’m curious as to what difference that patch will make compared to the neck tenon?

I’m curious as to what difference that patch will make compared to the neck tenon?

@mattbeels Wrong thread man. 😁

@boo aww give me a break!

aww give me a break!

@mattbeels 🤣🤣🤣🤣🤣

Hmmm - so to hide the neck tenon, you've glued in another piece of wood?

I'm curious as to what difference that patch will make compared to the neck tenon?

(@mattbeels)

Hmmm - so to hide the neck tenon, you've glued in another piece of wood?

I'm curious as to what difference that patch will make compared to the neck tenon?

@tv101 I’m not biting. 😆

OK! Time to bring this repair together. ✊😁👍

Glued in the blanks to fill the massive hole through the body. It’s a bit of a patchwork but once everything is routed flush and a little bit of filler work has been applied, it’s well on the way to being a half decent repair.  

With the glue dry, I routed most things flat and flush. There were holes and seams that needed dealing with so I got the filler out. It’s strong stuff this filler. After applying filler and sanding it back, I used extraction and a blow gun to clean out every nook and cranny to see what still needed doing, if anything.

What a rebuild @boo. 👍🤯 

🙏🎶🎸🙂 

Good work @boo. I especially appreciate the shots of the blow gun. Real subtle. 👍👍