@darrenking Ply patches work ok for this type of cavity repair as long as they are good enough quality to stand up to being routed with home equipment. Sometimes the cross grain causes tear out, remembering that part of the…   Read more»

@robin
I only filled in the tremolo cavity to fit a different bridge style which covered the repair, didn’t touch the pick up cavities.

@darrenking CNC machined blocks and templates would be a tremendous time saving for repair jobs. It would also take away a lot of stress for builders knowing there is an easy fix for mistakes. Hand making and fitting stuff like…   Read more»

@tv101 Yes risk assessments are very familiar territory for me. At work we had workshops with vehicle maintenance, wood machining/assembly and metal work/welding. I did all the risk and related assessments. We had to work to industry standards set by…   Read more»

@steveadams
Don’t forget the COSHH, Manual Handling and Power Tool Vibration Assessments (calculator for the last one is at http://www.hse.gov.uk).
ps don’t use a dust extractor, it will need a fire risk assessment.

@boo I’ve done a similar type of job where the owner wanted to remove the tremolo bridge and fit a fixed one. I did it by creating a template to fit the tremolo cavity using thick Perspex and then used…   Read more»

Rubbing the two surfaces together after the glue has been applied but before clamping helps to mate the surfaces together and prevent slipping after clamping. It’s known as a rubbed joint as opposed to a rolled joint which is something…   Read more»