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Hello all. I've got an interesting situation that i'm hoping i can get some help with. I'm building a stewmac ooo kit. in building the internal mold from the instructions, i made the outside u-shaped wood structure a bit too wide as i was nervous to crack the wood while sliding it on (it was making some real scary noises). in turn the waist of the guitar was just a smidge wider than the soundboard. i tried to squeeze it in while gluing on the soundboard but it didn't quite make it all the way in. i realized that i could use an extra long quick grip clamp to squeeze the waist when gluing the back and it worked great (sort of wish it would have been the reverse). I routed and bound both top and bottom (came out great) and what i'm left with is a gap between the binding and the soundboard (and the kerfing as the floor of the gap). the space is approx 1/8in at its widest point.

The question is: what to fill it with and how? would mixing superglue and spruce sawdust (or mahogany for a contrast look) and then scraping/sanding work? I have some extra scrap plastic binding. is there a way to melt that in to the space and scrape/sand it clean. any other ideas?

thanks

No glue and dust in that would stick out like a sore thumb , You can use this as a design enhancement opportunity. I am sure you discovered that the inside mold is not the best way to make a guitar , so what can you do , well what is the gap that is there ? I think w herringbone purfling and maybe a b/w -b/w/b pufling will cover the gap , you would have to remove the binding and redo it , but that would look like nothing was wrong.
you are not the first to do that , and adding some purfling will help

thanks for the tip. agreed, that internal mold is crap. i will say that most of the blame is on me as i didn't put the mold on for approx 2 weeks after the kit arrived. i think the bent sides probably widened a bit while sitting unsupported.
i like the idea of the purfling. i dont like the idea of re-binding, but i man's got to do what a man's got to do. i think i'll try a couple different experiments first on scrap wood. if no luck, then the binding comes off

thanks

Yeah, too bad you didn't ask before binding the first time. Live & learn.......we all go through it. No shame in asking before proceeeding if you are unsure about proceeding. Again, we've all been there.