Current build is 1/4" thick all around. The output jack and volume control will not extend far enough to grip threads to tighten. Aside from back drilling to back not seen hole larger, any ideas?
Thanks

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Brent if you have a Dremel you cand get a drum sander that will let you thin the material from the inside so as not to damage the finish. A quick and easy way to solve your problem.

you  can also  cut a large hole a bit  bigger  than the  pots  combined,  and  make a  "plate"   with  thinner wood (or  a piece  of pickguard)  for  the  pots . glue  on  , or screw on top .  

I have also used a long stem output jack...

I try to keep long shaft pots on hand for amps. The bigger boxes are almost always the thick ones. Have some inexpensive ones on the way from eBay vendor, hoping they are as high quality as they looked.

Mentioned in other thread. You can back or front route the project. You'd need a Dremel, 565 Multipurpose Cutting Kit, and router tip. You'd be done in under a minute, maybe two if you had three spots to route. 

Lowe's and Home Depot sell 3/4" brass closet door finger pull inserts. You get 4 to a pack for less than 3 bucks. Drill hole in the center for the jack, drill 3/4" hole through the box and tap into place with a hammer.

Or take away some material with the Forstner bit like Wayfinder suggested.

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