Building without a router

Posted by Jacob Blackwood on March 29, 2009 at 1:24pm
I have been using a wood file/rasp to notch the neck for the box on my guitars since I don't own a router and can't really afford to buy one right now. Is there an easier way to do this than the time-consuming, tedious method I am using? I have also tried using a chisel, which works faster, but isn't very nice looking once i have finished. Update: Two good solutions that were presented to me in the chat, in case anyone else was wondering what a good solution would be: 1. Use a jigsaw and cut an X pattern where I want the notch. 2. Use a 22mm bit and drill lots of holes and then sand off by hand. I think both of these solutions will work better than the file/rasp and chisel method I have been using. If anyone else has suggestions, feel free to fire away.

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Replies

  • Michael Gajeski September 11, 2009 at 5:41am
    I use a table saw. Lay your neck blank face down on a cross cut sled and make multiple passes with the blade height set just shy of your desired depth. works like a charm with minimal touch ups needed afterward.

    I have to say though, ted crocker's idea is pure genius as usual.
  • Jacob Blackwood April 6, 2009 at 2:39pm
    Update: Got a dremel with the plunge router attachment. Goodbye router woes!
  • B Tal March 30, 2009 at 10:45am
    Hey Jacob, I had the same issue before I got my band saw, I used my pull saw to cut in perpendicular cuts to the neck (like ladder rungs) about an inch apart for the length of the notch. Make the cuts a hair more shallow than you actually want the depth. Take a screwdriver and "pop" out the sections. You can remove alot of material this way quickly. Then finish up with the rasp/files. Ive done this on headstocks as well. good luck!
  • Jacob Blackwood March 29, 2009 at 2:30pm
    Thanks Randy. Both methods you guys told me about will be a lot easier than the method I was using.
  • Roosterman March 29, 2009 at 2:23pm
    Hope the gurus sorted this out for ya Jacob! My jigsaw is wrecked so I do it with a drill - Il attach a pic as its easier to see what Im on about (this one, bottom left, is drilled, just needs sanding). Basically I mark the 2 end points, cut it to depth with a hacksaw, then drill out all the material inbetween with a 22mm drill. Its a five minute job, quick belt sand and its done. Sure it leaves a row of little holes, but its inside the box....

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