| Make a template...it will be great practice for making the real thing. For this I'd use 1/4" plexiglas so that you can see through it when it comes time to position the template and trace it out on the body. Use a scroll saw or a thin bandsaw blade to cut it out (you can cut into the pattern from the edge and it won't affect the shape too much) and clean up the edge with files and sanding sticks.
Use the template to draw the shape onto the body, then I'd use small forstner bits on a drill press to remove the wood, and clean up the edge just like the template. You could just draw the F-holes by hand on the maple, but with a template you KNOW the shape will be identical if you're doing matching F-holes on either side of center.
You could also rout it using the template, but traditional-shaped F-holes would require you to use a 1/4" (or smaller) flush-cut bit without a bearing, and the spinning shaft rubbing up against the plexi template will cause it to melt and deform....and you'll end up cutting where you don't want to.
A plywood or masonite template would fix that problem, but to me the advantages of being able to see through a plexi template win out.
BTW a really easy (albiet slightly costly) way of making accurate masonite or plexi templates is to find a local laser engraver who will accept your DXF file and knock one out for you. Mostly these guys make their business cranking out plaques and trophies for corporate incentive programs, local sports clubs, etc etc...if you live near a metropolitan area, chances are there's one near you. Look in the yellow pages under "trophies". |