Insignia Guitar Body

Cut three pieces of 3/4in plywood down to 19" square and glue into a block. Drill a 1/8th" reference hole in one corner (approximately a 1/4 in from one corner).

Route a half inch channel along two sides for clamping (the stock is too large to be clamped conventionally.

Clamp the stock so that the reference hole is in the near left corner (0x0). For all steps align the tool with this hole.

Using a 2" 3/8" Straight Bit carve 1001 and 1002. You may find that you have to shift the router up a little, and may still not have space to use the probe. This project is right on the limits of the X Carve.

Switch to a 1/8th Straight Bit, again aligning with the reference hole, and carve 1003.

Setup complete.

Estimated time: 90 minutes

Flip the stock so that the reference hole is in the near right corner. For all steps align the tool with this hole. It is easier to do this whilst the 1/8th bit from the previous step is still in the router.

Using a 1" facing mill carve 1004.

Switch to the 3/8th" straight bit and carve 1005.

Finally, switch to the 1/8th bit for finishing and carve 1006.

Estimated time: 120 minutes

Because of the size and tolerances we've found that its easier to release the body from the stock using a bandsaw instead of tabs (which have a tendency to break during carving).

Just follow the contour of the body close enough for sanding.

Estimated time: 10 minutes

Bring the body to final dimensions and smooth out the bevels with a belt sander.

Switch to an hand sander for paint prep. Now is a good time to fill any imperfections in the plywood that carving exposed.

Estimated time: 30 minutes

Even if you're trying to demonstrate the beauty of plywood (and who isn't) I'd still recommend some form of finishing. If used as an instrument its going to be exposed to your sweaty paws whilst you are playing.

At a minimum some wipe on poly.

Estimated time: 60 minutes