How to widen holes for a toggle switch?

[BobBarkerBeast]

Hey all, I've taken my tone pot out and I would like to put in an LP Style toggle switch but the hole isn't wide enough. How should I make the hole bigger without altering the finish? Thanks!

[Bussman]

Don't use a regular drill bit! Use a reamer bit and go slow. You could also use a Dremel tool with a small sanding drum, again a slower speed is best.

[Stike]

Step drill

[Don A]

Enlarge the hole slightly by hand with a tapered ream.

[VTX-XTC]

Ditto on the tapered reamer....

[Diablo]

Yes, tapered reamer is the best way to go.

[RL in Fla]

Sears has reamers for way less than $tewmac's price .

[pmcqueen]

I wrapped some 220 grit sandpaper around a screwdriver with a decently large diameter shaft and went at it.

turned out pretty freakin' alright considering it isn't a very precise method, nor easy on the forearms. didn't affect my finish at all. ymmv.

[BobBarkerBeast]

Thanks for the tips guys! I've got a reamer somewhere, if not, I think I'll go with the Dremel method. I appreciate the suggestions.

[Don A]

Originally Posted by pmcqueen

I wrapped some 220 grit sandpaper around a screwdriver with a decently large diameter shaft and went at it.

turned out pretty freakin' alright considering it isn't a very precise method, nor easy on the forearms. didn't affect my finish at all. ymmv.

As long as you're careful, this works!

[reeced]

Can I humbly offer an alternative suggestion - replace the tone pot with a rotary switch. This will give you all the options of the toggle switch, and more if you want. Also you won't have to ream the hole, and you can have matching switch and volume knobs.

[xntrick]

what's wrong with using a drill bit?

[Bob V]

Originally Posted by xntrick

what's wrong with using a drill bit?

It's simply the wrong tool to enlarge an existing hole. Either it will give you a figure-eight shaped opening, or it will grab the wood and rip out a chunk of finish before you can control it. Some people say to use the bit with the drill running backwards. Still the wrong tool for enlarging and rounding out a hole.

Machinists use the tapered reamer all the time were the results have to be precise. Drill bits don't drill clean round holes - think about it they're two fluted cutting surfaces with relief behind them and the bit can wobble as it turns. To get a perfect hole, you drill almost to the size you want then ream it out with a reamer.

[fretshopnj]

BobBarkerBeast,
You didn't mention what kind of guitar or finish. If it is a nitro finish you can soften the finish around the hole with a Q-Tip and a little lacquer thinner. Just dampen the Q-Tip and run it around the inside edge of the hole enough to wet the edge of the hole and wait a minute or two. It won't make the hole bigger, but it will lessen the chance of a chip around the hole with any method you choose to make the hole larger. I usually do this, followed with a tapered reamer.

[Bussman]

Originally Posted by xntrick

what's wrong with using a drill bit?

Try it and get back to us. I'm not being a smart ass, that's how I found out.