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How would you attack this?

A friend of mine wants to replace the pickups in his LP clone (carved top). Currently he has P90's in there and he wants to put fralin p90s in it. The covers are just a bit too big for the holes -- I mean just a smidge too tight... the real work needs to be done at the corners. The older pickups were more round on the end, these are more square.

The pickup cavities go down a ways so sanding them seems ... "imprecise" and the top edge is going to need to remain clean. I was thinking routing them just a tiny tad bigger, but I am not sure how to jig it up. If it was flat it would be a cinch, but with the carved top I am a bit stumped about how to set a ring at the right size location.

Any thoughts?

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Brock Poling
Columbus, Ohio
http://www.polingguitars.com

If it were me I'd build a bridge type arrangement over the instrument, with the pickup route template cut in it's "roadway". You'd have to support the instrument properly at the right angle which can be tricky, but a similar system the the one we use with acoustic binding jigs should do the tick.

Make a jig like the Bridge Slotting Mill, that sits on the edges of the top, and rides a flat surface over the top, and put a template to guide the bit. If it wouldn't reach deep enough, you could then finish it up with a top guide bit, riding on the already re-cut top edge. Just thinking out loud.

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Waddy

Photobucket Build Album Library

Sound Clips of most of my guitars

I would free hand it with a round file or a dremel. Lots quicker and when all is said and done, probably just as accurate as a time-consuming jig.

I'm with Barry on this one. I have several small, not-too-agressive bits for my dremel wand that I do this type of thing with. It gives good results and doesnt get out of hand easily.

I would start out by tracing the outline of the new pickup by placing it over the hole of the old one and drawing with a sharp pencil, then route out the little amount needed. If it is really a small amount, perhaps a sharp chisel would be a better tool?

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Reguards,

Ken H

Recently I enlarged the pu holes on a cheap 335 knock off. I taped my stewmac router template to a big enough piece of mdf with double sided tape, routed it is that became my template. Then I taped some plastic food wrap to the top of the guitar, put a few dollops of auto body fiberglass bondo on a pressed my mdf template to it, hold it level. After it set up I took it off the guitar, removed the plastic wrap and then had a template that would sit flat on the guitar. I used masking tape on the guitar, doublesided tape to hold the mdf in place while I routed.

Sounds like a lot of work that a file could have done much faster, I know..

stefan

'had to do this many times, i'd say steady freehand would be fine, as long as the cutter is clean and working well.
if its just a tiny bit it may just be paint thats pooled there, you may be ok without even going right through the paint if its that small an adjustment.

i understand why you might want to jig it up, but the chances of creating a new nick or scratch are greater if you go down that route than a quick whizz over with the dremel.
good luck

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www.theguitarrepairworkshop.com

Definitely the Dremel. Unless you plan on doing a lot more of these pickup installations on carved top guitars, I don't believe making a jig would be worth the time.

man... you guys must have a steadier hand than I... On these P90s you will really see it if you get an uneven cavity. There is no pickup ring to cover inaccuracies.

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Brock Poling
Columbus, Ohio
http://www.polingguitars.com

Will the old covers fit on the fralins? Just askin'.

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Mike

The only thing nescessary for evil to thrive is for good men to do nothing.

Will the old covers fit on the fralins? Just askin'.

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Mike

The only thing nescessary for evil to thrive is for good men to do nothing.

make a flat routing template from ply, plastic, whatever, and use friendly plastic or bondo to make it fit the top contour exactly, secure it and route away.