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View Full Version : TUTORIAL easy pictorial for filling bridge, trem or pup cavities.



nitroburner1000
12-07-2017, 12:45 PM
This is an easy tutorial with lotsa pics for anyone who is doing a tremelo, bridge or pickup modification and wants to fill in the routed cavities. I looked and think this is the only one on the forum, if there is can someone let me know and ill delete it, cheers.
The reason im putting this up is that it was something i wanted to do but was very daunting, even though i did a lot of reasearch there wasnt many pics to look at, so here goes....

PLEASE NOTE.. THIS IS MAINLY FOR A GUITAR THAT HAS A SOLID PAINTED FINISH. IF YOU WANT A STAIN FINIISH LOTS OF CARE HAS TO BE TAKEN SO AS NOT TO DAMAGE OR GET GLUE ON THE GUITAR SURFACES. ALSO WITH A LIGHT STAIN THE ADDED TIMBER WILL ALWAYS SHOW, EVEN WITH A DARK STAIN IT WILL BE SEEN.

ALSO I WOULD LIKE TO THANK FORUM MEMBERS WHO CONTRIBUTED TO THIS TUTORIAL BY ADVISING ME ON ROUTING TECHNIQUES AND THE BEST SORT OF TIMBER TO BUY.

The tools youll need are different grades of rough sandpaper, from 80 to 120 grit, glue, a firm sanding block and chisels, and if you have power tools, an orbital sander, and router, and of course timber.

For filling the bridge pin holes i used tassie oak dowl...12.5mm x 1800, at a cost of about $7.50,
and for the cavities dar pine,.....64mm x 19mm x 1800 at a cost of about$12.
These can easily be obtained from your local hardware store.

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nitroburner1000
12-07-2017, 12:55 PM
Next.....filling the bridge pins...

I bought the dowl oversized so it needs to be sanded down to size then glued in, i used Titebond wood glue. Make sure its not too tight as you want a thin coating of glue on all sides of the dowl. If its a bit loose dont stress as you can use a goog strong filler like fibreglass bog to fix the gaps after. Bog is good as it can be drilled and sanded. Leave the dowl a lot longer as its easier to work with. I used a fine grinding wheel to speed up the process.

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nitroburner1000
12-07-2017, 01:02 PM
Once the dowls are sanded to size glue them and gently tap them in with a hammer until they are seated. Wipe off any excess glue and wait until dry before cutting flush.
You can use whatever saw you like just be careful of scoring the surface of the body. When dry sand flat and fill if need be, then resand until perfectly flush.

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nitroburner1000
12-07-2017, 01:11 PM
Measure approx size and cut. Not too much explanation needed here, the pics speak for themselves, just keep saning until exact size is reached. 2 pieces of this size dar pine fills the back cavity with about 2-4 mm raised, so you can sand after or rout and or chisel the cavity slightly deeper.

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nitroburner1000
12-07-2017, 01:21 PM
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nitroburner1000
12-07-2017, 01:34 PM
Once the pieces all fit glue them in, cleaning off any excess glue.

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nitroburner1000
12-07-2017, 01:40 PM
Next cut a smal piece of dar pine for the front fender bridge cavity and sandbto shape and glue in. This process can be used for any cavity, bridge or pickup.
PS i used pieces of timber and a heavy object to help the wood pieces to glue firmly.
Sand smooth, fill and sand smooth again. I sprayed on a coat of metho based primer, this helps to see what timber is still raised.When its dry sand again and keep sanding until all the primer is gone. It will then be completely flat as any raised or low areas will have primer still attached.

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THANKS FOR WATCHING AND IF THIS HELPS AT LEAST ONE PERSON ILL BE HAPPY. CHEERS.

pablopepper
12-07-2017, 01:41 PM
Tidy work, Nitro. Looking good.

nitroburner1000
12-07-2017, 01:45 PM
Tidy work, Nitro. Looking good.

Thanks Pablo, im slowly getting there....

FrankenWashie
12-07-2017, 01:45 PM
Good work on that Nitro. It's a good tutorial to have on board, as there are a few that would likely want to mod, though possibly not to this extent.

OliSam
12-07-2017, 01:45 PM
thanks nitro
i want your work bench!

wokkaboy
12-07-2017, 01:48 PM
good tutorial Nitro worked out nicely. Love the dead weight in the last post. Where you been dude been missing in action for a few months?

nitroburner1000
12-07-2017, 01:51 PM
Good work on that Nitro. It's a good tutorial to have on board, as there are a few that would likely want to mod, though possibly not to this extent.

Thanks Franken, i thought if i put up the extensive one then it can be a basis for any mod large or small, like you said...

andrewdosborne
12-07-2017, 01:57 PM
Thanks Nitro good tutorial one I need to bookmark

nitroburner1000
12-07-2017, 01:59 PM
good tutorial Nitro worked out nicely. Love the dead weight in the last post. Where you been dude been missing in action for a few months?

Yea Wokka , had a hernia op at the beginning of the year and was supposed to rest for 6 weeks but got stir crazy and went back to work after 2 1/2 weeks and ending up straining it and then ended up with an infection in the cut. Still sore now... hey thats life... back into it now.....

nitroburner1000
12-07-2017, 02:01 PM
thanks nitro
i want your work bench!

Hey Oli every man has to have a work bench even if its the kitchen table! Lol

nitroburner1000
12-07-2017, 02:01 PM
Thanks Nitro good tutorial one I need to bookmark

Cheers Andrew, was a huge learning curve for me...

wokkaboy
12-07-2017, 02:15 PM
OK Nitro, you should always listen to the doctor. Lesson learnt mate. You should rest up till you are fully healed.

nitroburner1000
12-07-2017, 03:26 PM
OK Nitro, you should always listen to the doctor. Lesson learnt mate. You should rest up till you are fully healed.

Thanks mate, appreciate the concert... but do we ever listen?....NOT

FrankenWashie
12-07-2017, 03:36 PM
Thanks mate, appreciate the concert... but do we ever listen?....NOT

The Bride of FrankenWashie keeps telling me that...something..middle aged men ....something.. Health...something???

nitroburner1000
12-07-2017, 04:49 PM
The Bride of FrankenWashie keeps telling me that...something..middle aged men ....something.. Health...something???

You must have a very understanding other half, mine keeps saying....old man.........lol

neverwas
15-07-2017, 10:03 AM
Well explained Nitro, recently went through the same process. Used meranti to try and better match the ash grain (close but not quite there). My edges aren't as neat as yours, had a few gaps on the back fill piece. No gaps on front piece and that one will be covered, oh well.
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Should really start a build diary for it.
Good to hear you're on the mend.

Grant

nitroburner1000
18-07-2017, 07:16 PM
Well explained Nitro, recently went through the same process. Used meranti to try and better match the ash grain (close but not quite there). My edges aren't as neat as yours, had a few gaps on the back fill piece. No gaps on front piece and that one will be covered, oh well.
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Should really start a build diary for it.
Good to hear you're on the mend.

Grant

A sterling effort Grant. Its not easy when you are trying to grain match, i must admit mine was easier seeing as i was going to end up painting it. Filler is my friend. Thanks for your concern btw.
So you now have me intrieged, have you finished it, what did it end up looking like? If there is no build diary can you post more pics?

neverwas
18-07-2017, 08:41 PM
Thanks Nitro. There's not much progress apart from routing for a Mustang trem.
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Original plan was to stain but that depends on how well I can disguise the patch on the back. Still a long ways to go.

Grant

nitroburner1000
19-07-2017, 04:57 PM
Thanks Nitro. There's not much progress apart from routing for a Mustang trem.
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Original plan was to stain but that depends on how well I can disguise the patch on the back. Still a long ways to go.

Grant

Well keep up the good work, i love these offset mod projects.