Tune-o-matic style bridges are very convenient for setting intonation but depending on how well they are constructed they can also be a source for some tone loss. A customer of mine has a pair of Gretsch archtops with floating bridges that he wanted to have replaced with solid bridges. I looked at the available offerings but I couldn’t find one that is fully compensated so I made a pair.
I drilled the stainless steel blanks for the proper post spacing and then milled the radius to match the freeboard. After adjusting the tune-o-matic bridges for proper intonation I measured the locations of each saddle and marked the locations on the prepared blank. The shaping was done by grinding and filing to the lines.