So I'm currently ordering another Romeo Anejo box because I'm really frustrated with how sloppy the pickup hole came out. I only have hand tools, no jigsaw or router, etc. Does anybody have any advice on how to be more precise while cutting the holes for the pickup? Thanks guys.
Aiden
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Mark the hole as accurately as you can and cut it undersized. Than use a file or sandpaper to slowly enlarge the hole to fit, or as Lane Martin mentioned get a pre-cut ring to hide any discrepancy in the hole.
Don't be afraid to make the hole too small at first.
I have no technique at all when carving pickup holes, sound holes or any other kind. :( My solution is to carefully trace the pattern I want in pencil, gently score the outline up to 2mm inside the pattern, carefully file to within roughly 1mm, then start to fit pickups (or sound hole rosettes) and use 120 grit sandpaper to sloooowly shape the hole until I have a tight friction fit.
Even with all my caution I still make mistakes with these clumsy manatee flippers of mine :D in which case I find that cocktail toothpicks, sawdust and Titebond can hide a multitude of sins...
Can't wait to see your build when you're done-and as far as your previous box goes, have you thought about shaping a piece of cedar lining to fit your overly-large hole, carving an insert from the cedar to glue into the hole and then starting the cut over? Might make a pretty pickup "border" and you're ordering another box anyway as a spare...nothing to lose, right?
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