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What would be the best method to fill a humbucker routing completly? I have a maple guitar body with 2 humbuckers, and I want to completly fill the bridge routing, and then paint over it to appear as it never existed.

get a piece of the same wood, cut to as near the same size as poss. and epoxy it in,

sand flat and refinish.

be warned though, you're fitting the new hardtail bridge onto the newly attached piece of wood and NOT the guitar body. I don't think anything other than epoxy would do it.

alte5rnatively route out a larger half thickness hole on the top. set in the cut to size opatch into this then you'll have a bigger glue area.

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Something else to consider is those inlay router bit sets .... you make a template, then use the bit and template guide with a bushing to route the pocket, then take the bushing off and route another piece as the inlay ... I would likely try this after filling the majority of the cavity with the same wood, hten do the top 1/8 to 3/16 with this. It should give a much tighter fit than you would get trying to sand something to fill, plus the glue line will be way tighter.

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Tony Karol
www.karol-guitars.com
"let my passion .. fulfill yours"

Here's a tutorial on filling trem routes.
Similar process

http://www.projectguitar.com/tut/tht1.htm