Comment

Comment by Dianne Woods on April 5, 2010 at 12:51pm

Thank you, guys. I will dremel sand on the inside until it fits. This is my second build. I will post pics on my page. The thickness of my box is 1 3/4". I thought this one would go a little faster, but not. I am still enjoying building it. The excitement is building inside of me as I work toward the finished CBG. Yall all know what it feels like---way out there. Thanks again for the help.

Comment by Wichita Sam on April 5, 2010 at 12:09pm

Easy answer to a too short neck on jack or pup is to dremel sand away on the inside until things fit... the nut and washer on the outside will make things square.... Sam

Comment by Outhouse Instruments on April 5, 2010 at 9:23am

I "chamfer" the edges of the hole on the inside of the box using an exacto knife.
usually this is enuff to let the shoulder on the jack sit in the hole and make room.
If not, I keep on "chamfering" unitl I can at least get the nut on.


Matt

Comment by Warren on April 5, 2010 at 9:13am

"and a spade bit the size of the jack." - Minor retraction. The second build was to tight for the spade bit, so I used a Forstner bit (which is not designed for use with a hand drill).

Comment by Warren on April 5, 2010 at 9:09am

Hi Dianne, I was just about to post this very question. The two builds I've done so far have had this same problem. To get through it, I used a poor quality 90-degree angle hand-drill attachment and a spade bit the size of the jack. I clamped the box to a bench and drilled from the inside to make foom for the jack. Same thing for the volume control. Very scary undertaking trying to stop before going all the way through the box. I've considered drilling a huge hole (so to speak) and then fitting the opening with a piece of tin. I don't really want to do that, and am also looking forward to ideas.

Comment by Dianne Woods on April 5, 2010 at 8:55am

Hey guys, I just drilled a hole for my jack in the end of my box. After inserting the jack, the jack doesn't go all the way through the box. What a dummy, I didn't measure it first. How do I fix it? Do I sand the place where the hole is on the inside, so the jack will go through all the way or what? Any suggestions would be greatly appreciated.

Comment by Wes "I'm Baaaaack" Yates on April 5, 2010 at 7:41am

Amen Jon. Always prototype if it involves cuts or tension. Template out anything you might go 'DOH!' over.

I just drilled some sound holes, one of which was supposed to be the 3/4" and I used a 1/2". Looked ok, that is it didn't look out of place but was still wrong to me.

-WY

Comment by Jon Pruett on April 5, 2010 at 7:22am

I drilled pilot holes into the end of a 3/8" thick piece of acrylic I intended to use as a tail stop. Couldn't support any tension at all - split open putting in the first screw. So I switched to a tail stop that's supported on the end of the box. The experiment left two empty holes in the face of the cigar box that continue to remind me of the value of trying new ideas out on scrap materials.

Comment by J.Hofmann on April 4, 2010 at 4:32pm

Yup. Just check my electric build... the pickup hole is a lil' bit wider the the pup cover...and that's just one of several on that build! LOL...looks like I'm in good company 'round here.

Comment by Brian Watson on April 2, 2010 at 8:26am

My deal is ..... Every one I build has a goof up of some type. It is the Dremel tool that got away, the measure twice cut three times and it's still too short, that's just about tight enough right there "SNAP", or the one more pass.... grind a 1/16th too much thing. It isn't just one it seems to be them all, but that just lets you know there all hand made.

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