So far knife and box cutter is all I've used. It works but it's very difficult. I'd appreciate any tools and or methods used by others to cut a space for wood to pass through. Thank you very much!

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Hi Vance,

Your response got me thinking... If you are doing a bolt-on neck, you could also use something like a long threaded metal rods (or two) between the neck attachment point and the tail piece to help maintain the strength of the cookie/cake tin when the strings are tuned up and the instrument is under string tension. So, using one or two long threaded rods, you could get by by just drilling 2 (or 4) holes in the sides of the tin, and you can use additional nuts on the threaded rod to tighten it to the tin sound box and to attach the neck, simplifying the construction of the instrument. I think maybe I'll give it a try in the near future.

-Rand.

Here's a diagram...

I'll add my two cents in. I suggest using a block of wood to support the tin when ether scribing your mark, punches or chisel are used. I also like to cut so I have enough hang over to fold back along the edge or dog ear onto the neck. Other wise there are several ways to clean and protect from sharp edges.  

i want my flaps to go reverse under the neck but im having a hard time figuring out how to cut the squares in reverse an access them as the squares are harder to cut at the base of the can where there is more of a thicker support beam. here's one of my not so pretty versions...sounds good though.

Attachments:

Yeh like wise... small holes and then cut between them with cutters, I used my fret snippers last time seemed to work .

or if you could use wood blocks either side, then use a hack saw and cut through the blocked wood and tin sandwich.

Once cut, remove the wood and you should have a clean cut. then you could probably use blocks as strengtheners inside.

and they should be the same size. A fine metal jigsaw may also work if you can get the right wood blocks inside. 

I was thinking on my last build I should have chased a slot in the neck, so it slid over the edge of the tin to hide the cut edge.

How do people finish the tin up to the wood?

 

Similar to how a banjo neck works.Strengthening piece goes through a hoile and joins to base of the neck.

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