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Thick box wall/paddle drill bit size

I already have several normal legnth size 1/4 jacks. What can I do to get the jacks in. Drill from which side with a paddle drill or other bit? The walls are a bit thick.

I just am editing this now...maybe I could drill from the outside of the box a hole bigger than I need. Then cover the outside of the box with some wood or metal...drill the proper size jack hole through that and attach? Will the jack be floppy though?

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Permalink Reply by robert jones on July 19, 2014 at 1:16am

Paddle bits do work if you get the good ones Bosch DareDevil bits run about $15 a piece but make very clean cuts.

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Permalink Reply by robert jones on July 19, 2014 at 2:36am

That should read $15 a set

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Permalink Reply by Jon Leslie/Runaway Veal Music on July 19, 2014 at 9:44am

These are kinda like the ones I found at Walmart ...they have holes drilled on either side and come in different shapes ...they could be reinforced and used as jack plates? They are a little thin bit prob ok. This is just a photo I found on the Internet...ones I have are more oval..can't get to em right now

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Permalink Reply by Mark Lindsay on July 20, 2014 at 3:13am

I got a bunch of chrome jack plates from CB Gitty, but I make my own brass, wood, plastic, or oddball jack plates as well. On some builds, a wood jack plate fits the overall "feel" of the build - especially if I use some scrap from the neck or fretboard material. In the case of fretboard material, I just sand it on my disk sander until it's thin enough to allow the jack to be secured to it with the nut and washer, cut it to shape and size, drill mounting holes, and give it a final sanding and finish it. They just take a few minutes apiece. If I'm using neck blank scrap, I resaw it to approximate thickness first, then sand to final thickness and shape it.

I've found that all kinds of things can be modified to be used as jack plates - flat 1 1/4" wide brass stock, polished stainless steel sheet stock, fender washers, bottle caps, a piece of an old pick guard, other odd scraps of wood or plastic. Basically anything that's mostly flat that I can drill through. I know that Randy Bretz makes some awesome looking plates out of bone and exotic hardwoods if you really want to go nuts. Really, the only limit is your imagination.

And I'll add another vote for Forstner bits over paddle bits. You can get sets or buy them individually - the choice is yours. If you're into dropping hints for gift ideas, a set of Forstner bits is perfect. My kids got me a set for Father's Day a few years back, and it only took me like 4 solid months of hinting. I think they got 'em for me just to shut me up, but whatever works, ya know...?

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Permalink Reply by Jon Leslie/Runaway Veal Music on July 20, 2014 at 8:33am

I like this subject of jack covers. many ways to go. I keep my eyes out for everything cbg ...I've become sort of a junk drawer scavenger...I find myself in the hardware isle of the store., dollar store ..whatever store...I know I'm not alone on this...never made a jack plate at all yet...I'm gonna practice before messing up a nice box...

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Permalink Reply by Mark Lindsay on July 20, 2014 at 11:39am

Welcome to the obsession. You'll never look at things the same way again. You'll try to think of a way to use everything you're about to throw away. Don't try to fight it - just relax, breathe deep, and go with it...

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Permalink Reply by Jon Leslie/Runaway Veal Music on July 20, 2014 at 12:17pm

too funny. I knew that was coming...

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Permalink Reply by John Sawyer on July 20, 2014 at 4:18pm

I just use my dremel with a barrel sander and grind away from the inside until it fits... lots of dust, occasionally some smoke when I get over-zealous, and it works...

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Permalink Reply by Jim Goodman on July 24, 2014 at 2:59pm

I have run into a similar issue with some JAVA boxes I got - I decided to give the cylinder style input jacks a try....

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Permalink Reply by Jon Leslie/Runaway Veal Music on July 24, 2014 at 3:22pm

How are they? Look long enough for sure. I always thought these are good for a strap holder ...sorta a hidden jack.

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Permalink Reply by Jim Goodman on July 24, 2014 at 3:42pm

They have them with a button end just for a strap, I had already drilled the hole low when I decided to go this route - I won't get them in until tomorrow. I hope to have my neck stained and ready to string up Saturday and can report back how it worked out.