Terry Stowell wrote:
Care to share your method of making a shim? (yeah I know, like making inlay filler dust, but some folks here will find it useful)
Oh, how I wish I had a method.
I will typically complete the neck set first (fitted, not glued). After that, I don't have any hard rules or procedures. Using feeler gauges or various wedges, shims you can fit under the end of the extension (with the neck clamped down) to find how much shim you want at the end, keeping in mind a bit of fall away is good. No formulas to figure how much is needed depending on how much you shaved off the heel or anything, you just have to check and measure.
Then I will sand a small wedge of the same material as the board, tapering to near nothing just before it reaches the joint. Check the fit of the shim, make sure it doesn't kick up the extension. Glue it on, fit the sides, occasionally touchup the shim, though often sanding to 240 and buffing will suffice. Then I will typically have to fit the bottom a bit more after gluing. Sometimes the shim has to be curved on the bottom to match a slight hump in the top (with a straight wedge you will often see a hump resulting in the board around the 15th-17th frets). Sometimes I do this with chisels, sanding blocks, or even sandpaper flossing at times.
As always, dry clamping and rechecking is key. There are tons of other variations on methods though. I have glued shims to the top before putting the neck on with the idea of being able to level the area with a long leveling block I made to reference off the bridge, but don't plan on doing that much anymore. It was an idea once, but really just took longer for me get the same results as the prior fitting method.
Bound boards are tricker to get a clean look. I've made spruce shims when they were small enough to blend in with the top. I'll occasionally do a bound spruce or ebony core for the shim, but it's so difficult to get a clean binding joint all the way around. I would love to hear some other opinions on this, as I've still not found an easy and reliable way to shim a bound extension invisibly. It can be done, but it's so dang labor intensive to get a clean line, and sometimes near impossible to match the ambered lacquer on white binding, or even the color of the binding itself. You can see quickly how a spruce shim can be more easily made obscure, blending with the top rather than blending binding in with the edge of the board. I'm more than open to other solutions here though.
So it's really a "whatever it takes" kind of philosophy for me. Generally glue on a shim, fit it to the top and to set the right angle, keep a bit of fall away, avoid the hump, sometimes touchup edges if necessary, sometimes before assemble (Martin), sometimes after (Gibson). Check everything well, get the angles right and make it look good. That's about all the advice I can think of at the moment.