Hello All. This is not strictly an acoustic guitar query but one that some of you might be able to help with. A customer has brought me his Danelectro Convertible (for those that don't know, a hollow-bodied electric, similar in size and shape to a Les Paul) to have the pot and end-pin jack replaced. He has opted to replace the original (broken) screw-in jack with a Switchcraft end pin jack. However, after completing the soldering, I have discovered that the tailblock is about 10mm too deep for the new jack - with the back cover and nut adjusted as far back as they will go, the barrel *only just* pokes through the hole, not even enough to get the outer washer and nut on.
To fit the Switchcraft jack would mean cutting a recess from the inside of the block, about 10mm deep x 15mm diameter - but I cannot see an obvious way of doing this short of opening up the body. Does anyone know of any clever 'hacks' for cutting such a recess by entering through the jack hole from the outside? Is there a special type of drill bit for this purpose (something with the cutting edge facing *towards* the chuck)? I'm thinking the sensible solution would be to revert to the original type of jack but, before I do, I thought I would field for ideas.
Last Edit: Jun 19, 2019 8:56:26 GMT -5 by mousecorns
Post by mousecorns on Jun 19, 2019 16:03:02 GMT -5
Thanks - that's the kind of thing I was thinking of! It's useful, but possibly not quite useful enough (to me) to justify the outlay - I can see why you made your own. Unfortunately, I don't have access to metal machining equipment, so I'll need to weigh up the the pros & cons of buying the bit vs. simplfying the job by fitting a different type of jack.