Today I got stuck into the headstock. For a template I used my standard 50s Stratocaster shape that can be sourced from here: http://pdfcast.org/pdf/fender-headstocks.
With the template printed out at 1:1 scale, I could get to work cutting the bugger out. This involved tracing around the template in pencil and then roughing the shape out with the jigsaw. Once the I had the rough shape, it was a simple matter of taking the curves down to the line using a combination of sanding wheel (for the convex curves) and a flap wheel mounted in my drill press (for the concave curves). I changed the inside diameter of the tight concave curve a little so that it fit my smallest flap wheel and negated any fiddly work with the half-round file.
She's now ready for sanding down to 800 grit. Yay!
cheers,
Gav.
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