Update, with pics
The cherry veneers from @dwizum arrived last week, and I already put them to use. First step was to cut some veneer to fit in each slot. All of my fret holes needed at least 2. I tried cutting them flush to the fingerboard at first, but they were too flimsy and kept breaking either while cutting, or when I accidentally bumped them. So I made them all about twice as tall as actually needed, and trimmed later:
I quickly learned that it was easier to work with the veneer, especially after I cut it to size, if the grain was horizontal rather than vertical; long streaks of grain good, short bad. This was really important for when I had to shave little bits of the veneer to maximally fill the fret gaps, given their uneven nature:
First step complete; oh and the clipboard is to catch as much debris as possible:
To secure the veneers, and further fill any minimal, leftover gaps and superficial scrapes, I used CA glue. No pics of that process, as speed was required to limit exposure to fumes. All the fans were turned on, and I held my breath as I worked with arms stretched far: I squirted a bead of CA straight from the bottle along both sides of where the veneer met the fingerboard, aiming to get as much as possible down into the slots. Then I squirted a bead in between the veneers to solidify my ply-fret-fills. I let it sit under a fan for ~24hrs, then I did what I wish I did many times over now:
After I taped the fingerboard, I trimmed the edges with a box cutter, using a
special technique that allowed me to hold the neck still and apply juuust the right amount of precise pressure:
Next step was to trim the tops, same tool; had to change the blade about halfway through:
Not pictured is me using the blade from my thumb plane and carefully cleaning up what I couldn't get with the box cutter. I removed the blade to make sure I didn't gouge anything while removing as much excess CA glue as possible. All done:
Some clean ply-fret-fills:
The worst ones where some of the veneer frayed and broke away as I trimmed em flush due to poor grain alignment (lots of little vertical grain instead of long horizontal grain) and because I didn't get enough glue between the plys:
I will have to go back and shove little bits of veneer in the large gaps, and just use glue to fill the smaller gaps. I'm much happier with this fill job compared to how it was. Even though it's not super prettt yet, it'll clean up just fine. And I'm confident it won't squish into a bow now.
As for the brick brack sent in return for the veneers, my original plan was to flatten out some aluminum like I planned to use myself, and then fit some sheets of that into an envelope with a square of toilet paper in between each. Well, I forgot I got rid of my cheap, crappy, albeit only iron (which I was gonna use to flatten the aluminum) so unable to make flat sheets, I couldn't send dwizum
"gold-plated aluminum" as planned. Instead, I'm sending something else tomorrow. Sorry for the delay in keeping my promise lol