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Making a simple bridge?

I want to make a simple bridge, similar to hundreds I've seen on the site here. Basically, I want a small piece of 1/4" thick wood with a bolt or screw (head removed) sitting on top, but inside a recess.

My question is what is the best way to gouge/file/route/drill out that recess "cleanly"? I want the bolt or screw threads to fit nice and level in the insert, and don't want it to look like a hack job.

Sorry if this is a dumb question.

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Permalink Reply by Dave Breault on April 6, 2010 at 3:53am

Not a dumb question at all, one thing to be acutely aware of is when you are dealing with power tools and very small parts it is very easy to have an accident. When I need to mill a small part exactly like you are describing I automatically reach for a hand tool such as a riffling file set or just a round file. It might take a bit of time to get the fit exact but compared to the set-up time you would need with a power tool I suspect you'd come out ahead.

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Permalink Reply by MichaelS Country Boy Guitars on April 6, 2010 at 4:56am

I second the hand tool suggestion, but if you could clamp the base down and have a steady hand a dremel with the right bit could do a nice job, it could also screw it up real fast too. : )

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Permalink Reply by Shawn on April 6, 2010 at 5:05am

I used sand paper wrapped around a wooden dowle to make the troff it was slow going but turned out great

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Permalink Reply by Outhouse Instruments on April 6, 2010 at 9:21am

Simple, quick and easy.
Get the wood for the bridge and sand, shape, whatever you wanna do, but DON"T do anything for the slot.
Now, get a piece of scrap wood .. the same as the bridge and clamp it on top of the bridge in a drill press vise. Clamp it so that you can see the line that separates the 2 pieces of wood. Now using a drill bit either exactly the same size or a fraction smaller ( best way), drill the slot where you want it by drilling on the gap between the pieces.
This could be done with a bench vise and hand drill, but the press is better.

Matt

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Permalink Reply by Dave Breault on April 6, 2010 at 9:28am

I like the drill press method, I've used it for other applications and it works great, never even occured to me

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Permalink Reply by Jkevn on April 6, 2010 at 2:57pm

If you dont mind the "slot" crossing the entire length of the "base", use a miter or fret saw and cut slots across it (long-ways)a few mm's apart. Then chisel the slot out and clean up with sandpaper/files. A depth gauge on the saw will make sure they are all the same depth.

Another option may be to rout the slot in a piece of larger stock....and then finish the base "around" the pre-routed slot...let us know if you find a good trick....

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Permalink Reply by Dave Onastik on April 6, 2010 at 7:02pm

The drill press method sounds pretty interesting. I wouldn't have ever figured that out. Thanks for all the helpful replies. I ended up using the cutting bit on my dremel to make a divit in a piece of oak. Worked well and looks ok, but I think I will try the drill press method next time.

I'll post some better pics later.

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Permalink Reply by Diane in Chicago on April 7, 2010 at 1:15am

Or you could come at it a different way: file off the bottom of the rod so it is flat. I did that so I could intonate the bridge but still keep the nice 'n' square position of the plinth part.