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http://www.thefretboard.co.uk/discussion/61134/sarge/p1
That's right, so most of the 1.5mm has to come off the top edge of the pocket to eliminate the very small overhang.
You can take half from the pocket and half from the heel to minimize this, but imo it's better to take from the heel alone, but that could limit that neck to that body.
http://www.thefretboard.co.uk/discussion/61134/sarge/p1
And its a job for a router and template. Too much to remove for the sandpaper on the heel method, and lets face it, 54.5mm is just too narrow.
The only thing to consider is the existing finish. If that has a lot of build up in the pocket it will be the reason for the smaller pocket. I would still use a router, but you may be okay with sandpaper if its just to clean up paint. I mask it all off. The tape protects the finish and helps prevent chipping
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I've used a router a number of times to enlarge pickup cavities and there has sometimes been some resultant very slight chipping of the paint finish at the edge. It didn't matter too much then because pick guard etc would cover it. At the neck pocket any chipping would be seen. I'll try routing with a template and masking the pocket edge as suggested by @WezV. I'm just a bit nervous about removing too much wood - it probably needs about 1mm off one side and 0.5mm off the other. I'll also be looking carefully at the relative positions of the existing 'bolt' fixing holes. Any tips on which bearing router bit type/size might be best @WezV?
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