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Step 10Drilling an Extremely Deep Hole
This is a difficult step. Start by drawing a straight line on the wood that will link the external jack through the back cavity, and continue on to the bridge pickup without hitting the bridge holes or tail piece.
For this you're going to need a drill bit thats 18" or longer. The one I had was actually a homemade unit, where a 3/8" drill bit was welded to the end of a steel rod. I believe store-bought versions are available. There are a few more complex workarounds for this, if you don't feel to ambitious to pull this off.
Then, lower the drill press down so you can fit the body in. Place the body in a padded vice with the marked drill line vertical. Using a normal size 3/8" bit, drill an angled hole into the body where you want the output jack to be. It should be close to the back cavity, and you should be able to drill all the way into that cavity. This will make life easier later on.
Lower the press down far enough that you can put the large drill bit into the wood and be able to get it into the chuck. Once it is lined up and the bit is in the chuck, clamp the vice in place so that it won't move. Its very important that everything is straight, or else the bit could come out the side of the guitar while drilling.
Start drilling down into the guitar. Make sure that the drill is perfectly straight when going in, and not flexing on an angle, otherwise the drill might burst out the side of the guitar. Move the bit up and down to clear the spirals of debris as you go.
Eventually you should see the drill enter the bridge pickup pocket. This will be the wiring hole for the pickup cables.
For this you're going to need a drill bit thats 18" or longer. The one I had was actually a homemade unit, where a 3/8" drill bit was welded to the end of a steel rod. I believe store-bought versions are available. There are a few more complex workarounds for this, if you don't feel to ambitious to pull this off.
Then, lower the drill press down so you can fit the body in. Place the body in a padded vice with the marked drill line vertical. Using a normal size 3/8" bit, drill an angled hole into the body where you want the output jack to be. It should be close to the back cavity, and you should be able to drill all the way into that cavity. This will make life easier later on.
Lower the press down far enough that you can put the large drill bit into the wood and be able to get it into the chuck. Once it is lined up and the bit is in the chuck, clamp the vice in place so that it won't move. Its very important that everything is straight, or else the bit could come out the side of the guitar while drilling.
Start drilling down into the guitar. Make sure that the drill is perfectly straight when going in, and not flexing on an angle, otherwise the drill might burst out the side of the guitar. Move the bit up and down to clear the spirals of debris as you go.
Eventually you should see the drill enter the bridge pickup pocket. This will be the wiring hole for the pickup cables.
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