Opening up humbucker hole on HSS pickguard

Cano

I've got a Jet JS400 HSS Strat style which I want to replace the Humbucker with a Humbucker sized P90.

The original pickup is an uncovered humbucker, the P90 is a covered pickup and has squarer corners. 

What's the best way to open up those corners on the pickguard?

Cano

Deleted double post

ICBM

A round file, preferably with the same radius as the corners of the humbucker cover.

Cano

ICBM said:

A round file, preferably with the same radius as the corners of the humbucker cover.

I'll leave the dremel well alone then. Thanks

paulnb57

Mark it out better than the photo with masking tape and use a round file to sneak upon the correct shape, just support it well while filing else it will flap about a bit.

Funkfingers

The original aperture was cut using a round bit. A round file leaves a plausible result. Flat files can leave tell-tale edges that look amateurish and wrong. 

Take it gently. You can always remove more material. You can't put it back.

Cano

Thanks, I've got a small round file ready and will remask and remark. 

Flip

Agreed, especially about the Dremel - power tools have their place but can often be the fastest way to make a mess of a project.

Cano

All done now. I just used a round file, then round needle files to remove the final bits of material stopping the pickup from fitting. The new pickup is in and sounding good.

I put a set of locking tuners from Axetec on at the same time as I hated the original machine heads and strings were already off. They held tune but were horribly stiff to use and the buttons were too small for me to turn comfortable or accurately.