DISASTER!!!

[Tony_in_NYC]

Hello fellas!
I will try to address all of the questions asked, not necessarily in order.
The white thingy (that is a technical term I learned from Martin Lane, Thanks Martin!) you see in the gap is indeed the truss rod.
This is a laminated neck made of mahogany with a bloodwood stripe. The bloodwood stripe is not a veneer, it is a solid piece of wood. You can see from other angles that is goes all the way through the neck.

The problem was not the thickness of the neck or the depth of the truss rod channel. The problem was ALL operator error. This neck is a standard thickness neck, I sanded it too thin. I got carried away and never stopped to measure the thickness. Stupid mistake. There should have been .15" of material below the truss rod had I sanded to a typical neck thickness.
The truss rod slot was routed to a depth of .475" and it is an aluminum U-channel truss rod.
I sanded the neck too thin here. It is now about .77" at the center of the neck, and you need to subtract about .25" for the fret board thickness. Too thin. I only left .50" plus or minus if neck depth. Since I did not use a thin truss rod, I made a mess of my neck. LOL

My major concern now, is that the truss rod might push the repair out of the neck when tension is applied. I am going to put some tension on the truss rod tonight to see how it goes. I might still need a new neck.

I am fortunate that I did not fully seat the truss rod in its channel. If I had, there would have been no room to insert my little patch. But, I might still be in trouble. We will see.

[Tony_in_NYC]

Well...I cranked on the truss rod until I induced a pretty good back bow in the neck and the repair held. I am leaving it there for a bit, knocking on the neck from time to time to see if it will hold. I think I might be OK.

[Ken C]

Way to save your neck! ;)

[Tony_in_NYC]

Thanks! I am still not entirely pleased with the look of the piece on the neck, but maybe it will grow on me, and its also pretty much out of your line of sight when you are playing.

[darren]

good time to learn how to do a burst on the neck, if you don't care for the look of the repair. just a thought.

[Tony_in_NYC]

Excellent idea Darren! I need to practice.