Hello all. Longtime lurker, first-time poster. Big thanks to everyone who takes the time to post - I've absorbed an incredible amount of information (and inspiration).
Anyway, I'm in the middle of my 2nd build (1st neck) and have hit a snag. The neck went together fairly well - truss rod installed, fretboard glued on, neck tapered to size, fretboard radiused, etc. I was thinning out the back of the neck when I broke through the bottom of the truss rod channel. It looks like about half the length of the truss rod route was too deep.
I was shooting for Ibanez specs (18mm thickness at the first fret, 20mm at the 12th), and used a Stew Mac hot rod. Stew mac says their rod requires a 7/16" deep channel (11.1125mm). So, in theory, there should have been plenty of wood left behind the rod. The route was admittedly a little sloppy (I was between routers, so I used my old dremel), but I thought it was going to work out. Guess not.
The neck is currently at about 21 mm thick; there is about 9mm of wood between the bottom of the rod and the back of the neck. So... If I were to plug that channel with a filet, would the remaining 6mm (9mm - the 3mm i have left to sand) of wood behind the rod be sufficient? The truss rod's force is exerted against the fingerboard, not the backside of the neck, right? Any tips for gluing in the filet without the glue binding up the rod? Or is this a lost cause? Should I just consider this a learning experience and toss it in the firewood pile?
Thanks guys. I'd appreciate any guidance that anyone can offer.