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OK Guys,
After never having to build or work on a slothead guitar before.
What is the preferred method for cutting out the slots after you glue on the EIR headplate?

Drill 1/16th inch pilot holes all the way through in the center of the slot. Then use a forstner bit a little smaller than your slot size and drill half way through from the front then finish by coming through the back. You will have zero chip out. Then use files and sand paper to smooth out the lumps and get your slots to final size. The only easier way is to get someone else to do it!

The slots are cut in the veneer using a flush cut router bit -- the 1/4" ones used for Formica will work fine the 1/4" or 3/8" bearing guided are even better.

For rounded string ramps take a piece of scrap wood and make it as wide as the slot, clamp that in a vise -- plane, file and sand a radius then cover just the radius with self stick sand paper. You glide that tool at an angle in the slot and create the ramp. If you are good with a chisel you could cut in some flat rectangular ramps -- not easy!

without power tools a coping saw and rasps and files. Ken's method works but as for Me I use a millling machine . What ever takes out the wood in a controlled manner will be fine

tippie53 wrote: What ever takes out the wood in a controlled manner will be fine

So then dynamite is out of the question? Dang.

For cleaning out the slots and making a taper for the strings, I used a dowel which, when it had 120 grit wrapped around it, did an excellent job.

I think shaped charges may work Tony

I did not try dynamite. I am not sure it is available and Rockliers or Woodcraft in seattle. I did use a router with a 1/4 down cut end mill bit. I also used a template I got from LMI and a template guide in my router. I used a rat tail file to get the string ramp.

Hey Tony, I'm not sure about the whole shaped-charge dynamite idea, but I'm reasonably certain my old stand-by implement of destruction a sawzall would help. To make it truly challenging I'd try it with a 12 inch bi-metal blade, skip the pilot holes and do a plunge cut. (and remember kids, if you've not tried it this way previously, ice helps stop the bleeding more efficiently...and open several band-aids since it can be somewhat difficult to tear open band-aid packaging with slick fingers when you're about to go into shock... after all safety first!).

' - it's important to remember:
Every tool in the toolbox is a hammer, EXCEPT a screwdriver, that's a chisel! '

I couldn't possible build (or un-build) anything without the trusty ole sawzall, and when a little more oomph is needed, his big brother "Mr. Chainsaw" is always on stand-by.

David L