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Today I use a coping saw blade, but it is rather imprecise and awkward. My needle files are too big but I can see a really small but coarse knife shaped needle file doing the trick. Does anyone make something like this? What do you use?

I use the Stew-Mac saw and clean-up/adjust with a set of Grobet machinist's files.

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Jim Howell
Charlotte, NC

I use a little saw that I got in a jack-o-lantern carving kit. It is similar to the StewMac saw. Kathy Matsushita use one as well and has a picture on here web site. (or at least she used to a few years ago).

No kidding-a jigsaw works great...and much better control!

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Sylvan
http://www.wellsguitars.com

I make my slots to match the width of each string. I start all the slots with a jig saw blade mounted in a handle. I ground the sides flat on a round needle file to make it narrower and it works perfectly for enlarging the 5th and 6th strings. I then use other needle file shapes for the next two wound strings. The jig saw slot alone works for the unwound strings.

I know some folks use a dremel/flex shaft with various bits.

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http://www.chassonguitars.com

[QUOTE=Sylvan] No kidding-a jigsaw works great...and much better control![/QUOTE]

He's alive!

Hi Sylvan. Merry Christmas.

After my last setup, I'm ready to try slotting one. What size jigsaw blade you using, it must be tiny? bd

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http://www.dickeyguitars.com

I took a dremel to a spare hacksaw blade:



It's crude but it works really well!

Bruce I learned that trick from Sylvan. I actually found some stock black and decker ones (smallest they had)at the hardware store that actually fit. If you find none small enough just take the smallest blade you can find over a grinder or belt sander. Double stick tape a piece of leather or felt to the sole of your saw so as not to mar the bridge (or pickup a cheapie B&D at a yardsale/flea market for five bucks and glue it on). The saw actually affords plenty of control because it is doing the work and all of your manual efforts are focused on guiding/shaping the slot.

Bruce -
Kahle answered your question. When I set mine up I just took a blade I had
on hand and ground it small enough to fit in the 3/16" hole. So, any blade
will do unless you can find one, as Kahle did, that does not need some
massaging.

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Sylvan
http://www.wellsguitars.com

I use fine cut Bosh jig saw blade (I forget the tooth and pitch) that is about 1mm (.039") thick for EAD mounted on a rosewood handle. and my Zona saw keyhole blade that I ground to fit the pin hole for GBE. I dress the slots with diamond dust impregnated micro-files to final width and radisued at the bottom of the slot

Lots of good ideas here... thanks everyone

I would have never gotten the courage on my own to try using a jigsaw with a modified blade. What a tragedy if it were to slip! It sounds like a good idea to try it on the test guitar first.