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Wavy joint

I've been thinking a way to make the bridge block(s). I think I'm making five individual blocks, each smaller than the bridge footprint and recess them to the body. After epoxying them I'm going to measure, drill and tap threads for bridge mounting screws. This way I should be able to make the holes in exactly right places even if the routed cavities or blocks were not 100% accurate.
Any thoughts?

Another way to do that is to make up a holding plate. An aluminum plate with all the mounting holes accurately located and drilled in it. Pre-drill and tap the five bridge blocks, then bolt them to the underside of the holding plate. This holds the blocks in accurate position in relation to each other while you set them into their beds of epoxy. You still lay out and rout the pockets in the body to get them very close to the correct positions. Try to minimize the clearance between the blocks and pocket walls that gets filled with epoxy. But the plate guarantees accurate positioning.

I also recommend that you use a screw in each bridge block to hold it down into the body wood, in addition to the epoxy. Pre-drill the screw holes in the blocks first, and epoxy them in using the holding plate. Epoxy may fill the screw holes, but that's okay. After the epoxy has cured, drill down through and install the screws.

I suggest the screws from experience: A few years ago, Keith and I did a prototype bass with an aluminum bridge block set in epoxy from the top. During testing, strung up, the bridge block popped out! That was embarrassing. The lesson learned was that the epoxy was doing a great job of making a tight fit; rigid contact between the aluminum and the wood. The block was a nice snug fit in the pocket. But the epoxy's bond on the aluminum wasn't that great. So it popped out. We popped it back in and added a couple of screws threaded down into the wood.

So I recommend epoxy plus screws for any bridge block that's set in from the top.
 
I also recommend that you use a screw in each bridge block to hold it down into the body wood, in addition to the epoxy. Pre-drill the screw holes in the blocks first, and epoxy them in using the holding plate. Epoxy may fill the screw holes, but that's okay. After the epoxy has cured, drill down through and install the screws.

But the epoxy's bond on the aluminum wasn't that great. So it popped out.

So I recommend epoxy plus screws for any bridge block that's set in from the top.

My armchair musing on this - give the outside of the aluminum some texture/shape for the benefit of the epoxy bonding to it.

I think I'd also lean towards drilling a clearance hole in the "holding plate" for the hold-down screw to allow screwing the blocks in place while the epoxy is wet. Pretty much a "gut feeling" on that one.
 
My armchair musing on this - give the outside of the aluminum some texture/shape for the benefit of the epoxy bonding to it.

I think I'd also lean towards drilling a clearance hole in the "holding plate" for the hold-down screw to allow screwing the blocks in place while the epoxy is wet. Pretty much a "gut feeling" on that one.

Yes, we always roughen up the outer surfaces of the aluminum bridge blocks with 80 grit on the belt sander, then wipe down with alcohol.

And yes, we normally install top-mounted bridge blocks with the screws during the glue-in.

On my Scroll Basses, I install the bridge blocks down in the depth of the body, as the top and back are glued together. I've got some special tricks with routing fixtures and drill guides to keep them accurately lined up as the epoxy cures.

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Bridge blocks and cavities done. Fit is so tight that the blocks are not moving at all. Blocks are 10mm thick. I’m going to drill and tap the bridge screw holes before epoxying. I don’t think I need any holding plate.
There’s filled holes from my mismeasures. They are mostly covered by bridges and string ball ends. To be continued after Christmas...
 
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