An item for our wish list for our fledgling parts makers...

[ken]

How about an aluminum block fixture that the cover can sit on? The tall part of the fixture goes all the way into the cover so the top of the cover is totally supported from the inside. it would probably look kinda sorta like a top hat.

Ken

[David Schwab]

How about an aluminum block fixture that the cover can sit on? The tall part of the fixture goes all the way into the cover so the top of the cover is totally supported from the inside. it would probably look kinda sorta like a top hat.

That's what you need... a drill guide. I made one for drilling the six holes for the string ferrules in the back of my Tele. I took a piece of wood and carefully drilled the holes using a drill press and fence. I then clamped that to the guitar and drilled the holes on the drill press with a brad point bit.

You can use a pickup cover as a guide for spacing. It's near impossible to get holes in a straight line without a fence on the drill press. And even then it's tricky. So you spend the time making a jig instead of ruining covers.

Just about every hole I drill in a bass I'm building has a template for positioning.

I've also made jigs like this that held hardened steel drill guides, which are ferrules that you drop into hole in your jig that you drill through. They are the same size as the bit (with a little extra clearance) and keep the bit going straight.

[JGundry]

Spence thanks for posting this information! Now just figure out how to draw your own humbucker covers and freedom from bad suppliers is within view.

[Spence]

You're most welcome.

[Joe Gwinn]

Drill jigs and bushings

That's what you need... a drill guide. I made one for drilling the six holes for the string ferrules in the back of my Tele. I took a piece of wood and carefully drilled the holes using a drill press and fence. I then clamped that to the guitar and drilled the holes on the drill press with a brad point bit.

...

I've also made jigs like this that held hardened steel drill guides, which are ferrules that you drop into hole in your jig that you drill through. They are the same size as the bit (with a little extra clearance) and keep the bit going straight.

Yes. These drill guides are called "drill bushings" or "drill jig bushings", are the standard industrial approach, and are commercially available for small dollars.

The typical approach is to drill and ream holes in an aluminum or steel "jig plate" (or just "jig"), press these bushings into the reamed holes, and then drill through the bushings in the jig. The bushings are bought to fit the drill bit quite closely, within a few thousandths of an inch, so one need not bother with drilling a pilot hole. Just drill the hole, and the bushed jig will force the bit to stay where it's supposed to be.

One can also buy bushings that are a slip fit in the jig plate, and are held in place with a small screw. This is done for two reasons. First, heavily used jigs may have bushings wear out, and a slip fit is easily replaced in place, without taking the jig plate back to the shop. I don't expect a pickup maker to be wearing hardened bushings out anytime soon, though. Second, if one has to drill a series of concentric holes, one can swap bushings, so long as the sizes are close enough that they all use the same size hole in the jig plate.

A "press fit" is where the bushing is about 0.001" larger than the hole it will go into, and the bushing is simply forced to go in. One can press bushings into place without an arbor press using a nut, bolt, spacer, and a large washer. Put the bolt through the bushing and the jig, with spacer, washer, and nut in that order on the other side. Use a wrench to tighten the nut. The bolt will pull the bushing into place.

Drills bits do not make accurate enough holes for reliable press fits, so one drills slightly undersize and reams the hole to size. To ensure that hole is perpendicular to plate, all this must be done on a drill press.

Press fit bushing http://www1.mscdirect.com/CGI/NNSRIT...MT4NO=16345196

Slip fit bushing http://www1.mscdirect.com/CGI/NNSRIT...MT4NO=16345622

Holding screw for slip-fit bushing http://www1.mscdirect.com/CGI/NNSRIT...MT4NO=16345622

Typical chucking reamer for use in a drill press to prepare hole for press fit of 3/8" OD bushing http://www1.mscdirect.com/CGI/NNSRIT...MT4NO=16346677

One uses a drill a few thousandths smaller than the reamer to make the hole. Reamers don't make holes, they only expand them slightly and clean them up.

[David King]

Slight change of topic but this guy came up for sale on craigslist in portland tonight...
http://portland.craigslist.org/mlt/tls/263348437.html
it's a "little" Enco injection molder, 1 oz size....

[Possum]

coool....

wish I had some munny.....Hey David I didn't know you were a Portlander? You ought to come to the Duff's jam on wednesdays and hang out with Greg Simon and me and play some guitar :-) I'm having a health crisis at the moment so haven't been there for almost two months but Greg goes every wednesday. Probably no jam tomorrow if the snow doesn't go away, we're snowed in up here in Battle Ground

[NightWinder]

Hello David, and Dave. I just got the iasco catalog. Thanks for the Link KIng. Thats a great deal on craigs list. The closest they have in comparison....1.1 oz. Air powered injection. Almost twice the price. I was going to go with it, but man......Bobbins are'nt the problem. LOL Dave. you should email and request the catalog. Something you could use however...the Thermo Vac. Check it out. I may opt for this instead. I thought of you first when i seen it......then i thought of me.......and then I thought of me some more.......226 pgs . Check it out. Pm sent here

[Possum]

video

now you got the catalog they have a video you can buy that shows plastic injection technique, might be worth buying if nothing else for education..

[soundmasterg]

David King, it would be fun to see you at the Duff's Garage jam on wednesday nights if you're ever able to make it. I met you probably about 10 years ago at a guitar/bass show when you were showing some stuff next to Saul. I was impressed with your basses.

Greg

[David Schwab]

I second that... I've only seen them in pictures, but David King does make some beautiful instruments.

[David King]

Thanks men. Now If I could just make some gwaddamned pickups I'd be feeling good.

[David Schwab]

Thanks men. Now If I could just make some gwaddamned pickups I'd be feeling good.

Hey I know the feeling! I can make the pickups, but I need cases for them... I think I'll start making some wooden cases.