Cutting a slot for a new selector switch

Flip · August 2023

Following up on an excellent suggestion here (of course!) I'm considering putting an Ibanez RG-type five-way selector circuit into a two humbucker guitar. At present the instrument has a single vol pot and a large 3-way selector toggle.

I'd normally start with the smallest hole I could fit my coping saw blade through then cutting a straight slot but I'm sure that'd result in too large a start hole and too narrow a slot.

I turn to the experts, please.

ICBM · August 2023

Buy the cheapest metal Telecaster control plate you can find.

Bolt it to the pickguard through the switch mounting holes.

Drill as many holes (diameter should be 1/16" or 1.5mm) as you can fit into the length of the slot, and clean it up with needle files.

TTony · August 2023

Are you cutting into the wood of a body, or the plastic of a scratch plate?

For the former, I've done the following;

Use a decent blade to score the line where you want the slot to be
Also mark the points where the mounting screws for the switch will go
Use a thin drill bit to drill holes at either end of the scored line
Then, carefully, drill a few more holes all the way along the line
You could put some masking tape either side of where the slots is going to be, as a marker/guide
That creates a fairly ragged mess of holes
Either use a thin file, or some sandpaper to join the holes together into one long slot, and tidy up the sides of the slot.

TTony · August 2023

It's how I did this one a couple of years ago ...

Image: https://tfb-user-images.eu-central-1.linodeobjects.com/7472f829ea680a76bed488a11966d8bafe6c80d617e4a8b22c

WezV · August 2023

I use a tele plate too, but join the hole swith a dremel and small router bit

Funkfingers · August 2023

Freeway 3X3-03 six-way toggle selector switch. Directly retrofits Switchcraft switch hole.

I would need to scratch my head a bit to suss out the exact wiring on the Freeway.

Flip · August 2023

As usual, I am reminded how much wisdom lies in these pages. Thank you gentlemen.. I should have made it clear that I am planning to cut directly into the wood, but your suggestions have covered that.

I also wondered about using a Dremel circular blade but my concern was that it's very easy to create a slit that's not exactly vertical. The telecaster plate 'guide' and a my pillar drill are appealing options to produce a line of drilled holes at the correct angle. I'm also reminded about my own advice to people about Dremels - that too often they're the fastest way to screw up a job.

I also didn't add that the existing cavity in which I'm planning to work is very tight. Routing additional space or even a new cavity are options. It may be possible to avoid doing that but I also want to avoid moving the existing pot holes which makes that aspect even trickier.

At worst I'll have to have the whole cavity enlarged which is something I'm neither equipped nor experienced at to do myself but happily I have an excellent and very cooperative joiner nearby.

Finally I'd wondered about Funkfingers' idea of a switch alternative but my ability with the wiring isn't up to that challenge, I suppose I could always ask another question here.

WezV · August 2023

Flip said:

I also wondered about using a Dremel circular blade but my concern was that it's very easy to create a slit that's not exactly vertical. The telecaster plate 'guide' and a my pillar drill are appealing options to produce a line of drilled holes at the correct angle. I'm also reminded about my own advice to people about Dremels - that too often they're the fastest way to screw up a job.

they are fine if used with care, and the right bit! A circular blade would not be good for this, but a router or grinder bit cleaning up a line of holes will generally work well and follow the path of least resistance

normula1 · August 2023

Tele plate worked for me too

Flip · August 2023

Just an update on progress while I'm waiting for the selector switches to arrive from Germany - three from Thomann inc delivery cost less than one from Alegree though of course delivery is slower! Gold plated Tennessee revivals from Warman are also ready to install in turn.

I found the forstner drill bit set I already had included one exactly the right size for the largest required and a set of smallish dremel routers plus my existing accessories were ideal for creating the cavity. I have some sheets of 2mm plastic arriving tomorrow from which I'll cut the new cover.

When the switches arrive I'll use the multiple 1.5mm hole technique recommended above followed by a 1.6mm dremel router using a tele plate as the guide to cut the slot, then finally drill and countersink the holes for the selector screws. After that it's the wiring and there'll be another upgraded, updated headless guitar to go on our Guitar-Art stand at the next Guitar Fair - with appropriate thanks to the generous folk here as usual.

SteveRobinson · August 2023

Flip said:

When the switches arrive I'll use the multiple 1.5mm hole technique recommended above followed by a 1.6mm dremel router using a tele plate as the guide to cut the slot, then finally drill and countersink the holes for the selector screws.

I drill the screw holes first, and use them to securely attach the control plate.

Flip · August 2023

Thanks @SteveRobinson. Obviously that's good advice - my thoughts were to make sure the 2502N switches were the same size but of curse I could check that against the tele plate first. Sometimes the most obvious things don't occur - maybe it's an age thing!

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Cutting a slot for a new selector switch

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