#1
I have done 3 guitars with the hot rod truss rods that are adjustable at the heal but I have seen some places where they rout the slot right to the end of the heal. I usually just rout it until the adjustment nut and than drill a hole for it. Would it be better just to rout through? I would think the truss rod would fall out though... I am in a position now where I either have to patch up the end of the neck and drill a hole or patch it up and rout to the end or I may just start another neck.
#2
I'd keep with drill the hole, looks much neater. Anyway if you did route all the way through the rod wouldn't fall out if installed correctly.