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Permalink Reply by jonnythumper on February 7, 2013 at 5:19pm

I'm working on this too...thinking a template & a router & lots & lots of patience...

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Permalink Reply by The Phrygian Kid on February 8, 2013 at 1:25am

If you're talking about a cigar box then I would consider a router extreme overkill, I just use an exacto knife and a sharp chisel

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Permalink Reply by Shawn on February 8, 2013 at 6:31pm

I use a Dermal with a router base and a downward spiral bit.

1.Mark out the neck pocket on blue painters tape on box then cut 1/8 inside line with an exacto blade of neck pocket line remove the inside portion of tape exposing the box wood to be remove for neck pocket

2. Drill small holes in corners and rout out pocket.

3. After major wood of neck pocket is removed sand pocket and keep checking for a tight fitting neck pocket.

I tried the jig approach but every neck I made was just a we bit different.

I use 1/8 spacing just because I have had boxes with small voids in wood and the Dermal can jump on yah.

This sounds labor intensive but it yields the best pocket results at least for me

P.S I spray glue different grit of sand paper to strips of wood and dowels to do the finish sanding this saves the knuckles.

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Permalink Reply by wayne niswander on February 9, 2013 at 5:44am

Shawn, Much thanks will try in next box.  Have ruined three boxes already, good fit but not a perfect fit.

Wayne N.

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Permalink Reply by Jim Woods on February 15, 2013 at 7:17pm

If the neck pocket can be cut open to the lid, I use the Japanese back saw I use for cutting frets. Then a coarse file to finish.  still not always perfect, but it is a stick in a box isn't it? - First have to make sure there are no staples.  

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Permalink Reply by wayne niswander on February 16, 2013 at 2:33pm

Jim, thanks for the update.  I have finally found the secret to cutting a neck pocket open to the lid.  Using the recommendation of Shawn plus a Japanese back saw and some definitive sanding, a tight and perfect fit.  Thanks to all who have responded.

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