Now this is a pretty easy job with the right tools... Exactly. The right tools being a router, which would polish it of in a couple of minutes. Instead I tackled it with a hand held powerdrill, and a screwdriver to dig out the scraps. I justify this to myself (apart form the fact I don't own a router) that Billy probably did the original in similar fashion - there's a note on his website about how he had to hoover the bits up from his Mum's front room carpet. Actually hoovering as you go along really does help, as you need to clear out the mess to see what you're doing.
Anyway, I tackled it in a couple of sessions, drilling out the corners first, then some bigger holes, and then bashing at what was left with a screwdriver. It worked OK, but did leave the hole looking like the surface of the moon - quite cool actually. However in a final conscession to using the right tools, I bought a nice new, and VERY sharp chisel, which did a great job of tidying it all up, squaring off the edges, smoothing the bottom of the whole, and then enlarging the whole thing slighly to fit the pickup in.
I actually amazed myself - I'm not the greatest craftsman and had pretty well resigned myself to some parts of the job being a bit rough (that is after all why fender invented pickguards!), but the final pickup route really looks good. It's totally clean, smooth and more or less square. It looks a pretty proffesional job!
Of course the control cavity also needs to be extended to contain an extra jack socket, and an extra pot. Basically the existing three sockets are used up by the P Volume, and the sockets, so we need to add new routing to fit the volume and tone pots for the EB pickup. I've made a paper pickguard template, and marked the control positions on it, so I just drilled through that, and enlarged the cavity from there. As there is not exact size or shape it needs to be, the end result is a little more messy than the pickup route, but should do the job (and it is covered up), so we're all good to go.
Next job is (I think) to oil the body. I eventually decided to try some Danish Oil (mainly Tung) to bring out the grain of the body, and make it look more woodlike. There's still some patches of the old finsh, so it might come out blotchey but I can always sand those out and re-apply if it oesn't work first time. We're not going for a perfect result. I'll probably need to put a thin layer of laquer over the top for the stickers, but I think I've got some acrylic spray somewhere, so I'll just give it a quick coat of that to seal it before I do the waterslides (I think)...



