Replies to This Discussion

Permalink Reply by Lane Martin on December 29, 2016 at 5:27pm

Speaking only for myself, slow usually works best. Also, there are rings that fit around pickups and can hide a multitude of errors.

Permalink Reply by Thomas "Duck" Petry on December 29, 2016 at 6:31pm

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.

Permalink Reply by MadGomer on December 30, 2016 at 1:05am

Lane and Duck nailed it. Only other thing I can offer is to use a sharp razor knife to make multiple passes over your pickup outline in the box in order for the saw blade or chisel to have a good path to follow. Patience is the key though, don't get in a hurry.

Permalink Reply by Order99 on December 30, 2016 at 3:35pm

 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?