I needed a three way switch on my latest project and didn't really have enough room on the pickguard for one, so i sunk a switch into the body, from the rear.
Sounds kinky, but here's how it went.
First I located where I wanted the switch and drilled a pilot hole thru the body.
Then I determined the size I wanted for an opening. I went with 1.5" for the cavity, as that would work with a Gibson type 3 way toggle.
I chose 1.75" for the cover opening and to leave a shelf for screw attachment.
Then selected the proper size hole saws and went to town.
I started with the 1.5" holesaw and cut in just a bit.
then switched to the larger 1.75" one and only went in as far as the thickness of pickguard stock.
Then went part of the way to my final depth with the hole saw and routed the material out of the center leaving a shelf.
Now I used the router to take the cavity to the final depth a bit at a time.
Then I found a steel flange that was the size of the opening.
And used it to transfer the diameter onto a piece of pickguard material.
Rough cut it on a scroll saw & got it closer on a belt sander.
The fit it home with files.
Located the screw holes & drilled them into the cover.
All that was left was to use a step drill and get the front opening to size & mount the switch.
Sounds kinky, but here's how it went.
First I located where I wanted the switch and drilled a pilot hole thru the body.
Then I determined the size I wanted for an opening. I went with 1.5" for the cavity, as that would work with a Gibson type 3 way toggle.
I chose 1.75" for the cover opening and to leave a shelf for screw attachment.
Then selected the proper size hole saws and went to town.
I started with the 1.5" holesaw and cut in just a bit.
then switched to the larger 1.75" one and only went in as far as the thickness of pickguard stock.
Then went part of the way to my final depth with the hole saw and routed the material out of the center leaving a shelf.
Now I used the router to take the cavity to the final depth a bit at a time.
Then I found a steel flange that was the size of the opening.
And used it to transfer the diameter onto a piece of pickguard material.
Rough cut it on a scroll saw & got it closer on a belt sander.
The fit it home with files.
Located the screw holes & drilled them into the cover.
All that was left was to use a step drill and get the front opening to size & mount the switch.
