The neck is now united with the body 😀 Here are the steps so far: -
1. I started with some 4.5mm down and needed to reduce it to just over 4mm to fit the holes so I stuck it in the pillar drill and used some 180 grit sandpaper to slim it down
2. Then I cut them in to approximate lengths and shaped one end to try and penetrate the holes as deep as possible
3. I put some glue in the holes and on the dowls themselves and tapped them home. After a few hours I trimmed the excess lengths with a wood chisel. This was a bit messy and I scratched up the finish on the heel of the neck unfortunately, but no one's looking there right? 😉
4. Next I held the neck in the pocket of the body and used a 4mm brad point drill bit through the body, which fit the holes nicely without much movement, to mark the position of the holes on the neck.
5. Then it was time to drill the holes! I clamped the neck to a slab of polystyrene. I didn't shape this because the neck just embedded in to it.
6. I used a spirit level and set square to get things as level as possible and perpendicular to the drill bit. I also set the drill so that the maximum travel matched the depth of the hole I wanted.However, polystyrene thing was quite tricky and wasn't really ideal because there was some movement (I'd seen a video on YouTube which suggested using a fretboard sanding block matching the radius of the fret board and that would have been a good idea if I'd had one!). In the end I gauged the pressure I was placing on the neck as I was holding it and made allowance for that and just went for it! Not quite the precisely controlled procedure I'd had in mind and the end result was a bit messy but it worked well enough.
7. I'm pleased with the finished result as the screws are tight and solid and the whole thing fits perfectly.