Body Routing & Cavity Modifications

A router bit spinning at twenty thousand RPM a few millimeters from a finished guitar body is not a forgiving place to learn. Cavity work means opening up a pickup route, deepening a control cavity, or cutting a new channel for a trem block, all in a piece of wood that already cost someone a week of finishing. The tech works from a template, but the template only tells you where. How hard to push, when the grain is about to tear, and when to stop and vacuum chips are things the hands know.

The job begins with masking and tracing. Painter's tape goes over the finish, the template is clamped or double-stick taped in place, and the tech checks alignment against the neck pocket and bridge holes before any cutting starts. Most routes are hogged out with a Forstner bit on a drill press first, then cleaned up with a bearing-guided bit in a handheld or table router. Depth is checked repeatedly with calipers and a depth gauge because a pickup that sits a millimeter too high is a return.

Our head-mounted camera rides at the tech's eye line, so the footage shows what they are watching: the bearing riding the template edge, chip load building up in the corners, the moment the bit enters end grain and the feed rate slows. Two fixed cameras cover the bench from the side and above. Audio is captured too, since routers tell you a lot by pitch.

Researchers get each job cut into steps such as masking, template alignment, pilot drilling, roughing, finish routing, cleanup, and fit check. Labels are plain language. Each episode carries a pass or fail tag for the finished cavity and notes any tearout or template slip. Hand, tool, and workpiece tracking can be added, and the whole package lands in your schema in your bucket.

The workers are consenting, compensated participants, and nothing here is restricted to research use. One business day after you ask, a sample batch with annotations is in your storage.