Advice on routing new pickup recess

[Pilgrim]

I'm about ready to have a go at routing the new pickup recess for the T-Bird pickup on my EB-0.

Any advice on whether I should make a template for the cavity, or free-hand it with a carefully created outline on the body?  I may have to tweak the existing pickup cavity as well.

[Dave W]

I would make a template, and depending on the situation I might plug the existing cavity.

[Lightyear]

Template and test it on some scrap first.  Also make sure you allow for the thickness of the finish when sizing the template.  The perfect snug fit becomes a PIA once you add finish - or so I'm told 

[drbassman]

+1, template and test.

[gearHed289]

+1, template and test.

+2! After working in the case shop here for the past 13 years, I can't BELIEVE the things I used to do free-hand with a router. Templates rule!

[Pilgrim]

Sounds like great advice.  I'll flip that PU upside down and trace, then figure out how much wider the template needs to be to allow for the bit and bearing.  A few 2x6 chunks can give their all for practice and adjustment.

[godofthunder]

Agree with all of the above ! Template and test !

[Bionic-Joe]

ALWAYS use a template and then test. Freehanding is for other purposes. You'd seriously regret it if ypou try to freehand it. My 2 cents.

[Dave W]

I can't remember, are these the standard guitar humbucker size from a LP Bass or the wider ones from a T-bird? If it's the former, you can probably find an accurate template .pdf online.

[drbassman]

I can't remember, are these the standard guitar humbucker size from a LP Bass or the wider ones from a T-bird? If it's the former, you can probably find an accurate template .pdf online.

Dave's right.  If the pups are the smaller LP pup size, you can buy the templates cheaply enough on eBay or Stew-Mac.

[Pilgrim]

I've emailed Stew-Mac asking them if their Humbucker Pickup Routing Template (#1094) is a match to my T-bird pickups.  My pickups have dimensions of 2 3/4" wide, 1 1/2" top to bottom, and the mounting tabs on each end stick out about an additional 1/4".  We'll see what they have to say. 

[Dave W]

That's standard guitar humbucker dimensions, give or take a thousandth or two depending on manufacturer. Bartolini's page gives the dimensions as 2.75 in x1.52 in.

I found the attached routing template at the Tele forum, he did not put in the corner radii because he predrills the corners at 3/8 in. and uses a converted milling machine instead of a router. I can't vouch for the template dimensions but I can measure an opening in an old pickguard if you wish.

Of course, using a square template with a router still gives you rounded corners, just use the proper radius bit.

[Pilgrim]

Thank you very much, Dave!

That sure looks right!  That template just adds 1/16" in each dimension...and my measurement was a 'skosh (note highly technical language used for accuracy) smaller than the lines on the tracing I made.

If that's the case, I may buy the $6 template from Stew-Mac.  Howsomever, I picked up a chunk of masonite today and might try making my own...if I can find a couple hours to spare.

[Highlander]

You'ld need a template for the template... 

[Pilgrim]

You'ld need a template for the template... 

This has not escaped me.  It would take a good deal of time to make a template from scratch - when one has never done it before.