Routing The Latest Batch Of Envirocasters

Today, I finished routing all four of my current batch of Envirocaster bodies. At this stage, each Northern Ash body weighs 5.8 pounds. That's about 2.5 pounds heavier than if the were made from Swamp Ash. I know some people are picky about weight, but IMO, tone and sustain are far more important. In my experience, the best tone and the most sustain comes with a slight weight penalty.That being said, my goal is to hit about 9 pounds for each of the finished guitars. That's about what a Les Paul weighs.

My control cavities are made by drilling out the area with a 1.5" diameter forester bit. Then I rout the cover shelf with a template.

The double cutaways will get three single coil pickups.

The single cutaway will get a pair of P90s.

Plumbing An Electric Guitar

The photos below show how I plumb a solid body electric guitar for wiring. Oh, and don't forget, you can download the plans by clicking here for this guitar and the double cutaway version FREE during the month of March.

To drill the jack hole, I start by using a 7/8" Forstner bit and drill about 1/8" into the side of the body.

Next, I drill out the wood with a regular 1/2" bit to make it easier for the Forstner bit  to drill  into the control cavity.

To run the neck pickup's wires through the bridge pickup cavity and into the control cavity, I drill a 1/4" hole with an 18" long bit from the neck cavity all the way into the bridge pickup's cavity.

Finally, I drill another 1/4" hole with the same long bit from the bridge pickup's cavity down into the control cavity.

To make the slot for the 5-way lever switch, I used a 1/8" straight cut bit in my router.

Routing An Electric Guitar Control Cavity

The photos that follow show how I like to rout out the control cavity for an electric guitar:

I use a template in conjunction with a 1/2" diameter, 1" long pattern trimming router bit to rout the pocket. The depth is within a 1/4" of the front of the guitar.

This is the template I use to make recessed cover shelf.

To rout the recessed cover shelf, I use a bushing guide with a 3/8" straight bit.

The router in action as I cut the recess for the cover. The depth is about 1/8" below the back surface.

All that's left to do is drill the holes for the switch and pots and make the cover.

Cutting Out An Envirocaster DC Body

Today, I made a couple of Envirocaster bodies. Here are some photos of how one came to life:

I used a template made for me by Ronny at guitarbuildingtemplates.com.

The body is Alder with a flamed Maple top.

I used a Wagner Safety Planer to thin the body from 2" down to 1-3/4" thick.

To round over the edges, I used a 3/4" round over bit in my router.

Tomorrow, I will rout the control cavity and drill the jack and wiring holes.