OK, the pictures you linked to shows the Fender bi-flex trussrod. Thats the one I linked to in my first post. To do that type of trussrod the original way you rout a curved channel from the back of the neck. That doesn't seem to be what you want to do. I try to understand what it really is that you want to achieve. Do you want to use a straight channel, double action trussrod, placed directly under the fretboard, but have it look like the Fender bi-flex trussrod? If so this is the way I would do it:
- Use a lathe to turn walnut plugs with a hole in the center to match the Fender style plugs (or buy them ready made, they cost from 5$ plus shipping and import taxes but if you don't have access to a lathe you have no choice...)
- Rout the trussrod channel from the top of the neck blank. Stop before you reach the nut area (draw this out full scale for the actually measurements). Like this 105392d1323672833-installing-martin-1-way-truss-rod-flat-headstock-2011-12-12-17-02-07-jpg
- Cut the headstock to desired thickness but leave the fretboard end squared off, not like the smooth curve it will have when finished. This makes it easier to do the next step. Like this: 02-tr.jpg
- Drill a hole to match the plug you just made and make sure you have the center of the drill at exactly the same position that the adjustment nut of the trussrod have. quite similar to whats done here, altho at the head stock and without a already cut channel and with standard drill bits.
- Insert the plug and check alinement, fit etc, glue it in when you know the fit and placement is perfect and proceed with shaping the neck.
It can also be done without the plug, just drill a smaller hole, like this: trussrod_565.jpg
Now to the original question: How to make a double action trussrod. Are you seriously saying that getting the trussrod from here in Europe is to expensive? 10.90 from Rockinger, I see that Madinter in Spain have the Gotoh style straight trussrod (not my preferred version but I have used it over the years) for 9,31 and I know that there are more suppliers here in Europe (I get it locally for 15 Euro and I'm considering that a good price as I don't need to pay for shipping as I can pick it up by myself...). Shipping should be minimal if the one at Madinter is acceptable and a very small cost compared to ordering special metal working tools like the counter clockwise tap and die. I checked and here in Sweden the cost för a M5 counterclockwise die is around 60 Euro! And a matching tap is 30 Euro. So if you don't already have those (a cost of 90 Euro), or have access to tools like that, and on top of that cannot figure out how to make the trussrod from looking at the pictures; do yourself a favour and buy a ready made trussrod. It will save you a lot of time and money