More build shots, although some of these I think are getting out of order of execution. Still, in the interest of documentation...
In the last update, we'd installed the threaded inserts in the neck heel. Before you install the neck, it's a good idea to check to make sure your inserts went in straight so you don't cross-thread them. Gives you a chance to put the Fret Rocker of Precision to double duty...
Straight up at 90° to a side - should be good
Here we're trying to cut out a switch cover. Body didn't come with one, since that hole didn't exist at fab time. Besides, since the binding was predominantly cream, I wanted cream covers to match. I used a variable-size hole cutter, which is sort of a goofy tool. Kinda turns the drill press into a reverse lathe, where the part stands still and the cutter spins around the circumference. Throws the press all out of balance, and puts some unusual stress on everything involved. But, it's infinitely adjustable as to diameter within its range, so it has its uses. As you can see here, however, there is some risk to using one if you're as stupid as I am...
On the first try, I only clamped one side of the material and thought I could hold the other side against the force of the cutter by hand. Luckily, I didn't take my thumb off as the part rebelled against being cut and spun out of control.
No..no... Superman, he no here...
The second try, I got a circle cutout out of the deal, but it was too small. Third time (not pictured) was the charm.
Then we have to have a control cavity cover to match. Typical kidney-shaped cover, so I grabbed a loose one I had laying around and traced it onto the material. Plugged in the Jigsaw of Jeopardy, chucked a fine blade into it, and made a rough cut...
Things are looking up. Still got all my fingers, and what looks like something that with a little attention could be a cover. Life is good. And fair! Where's my beer? Small victories need rewards, too.
Dug out some double-sided tape and attached the rough blank to the template to guide final shaping...
Then went through some 80, 120, and 180 grit sandpaper to get the thing shaped to fit...
...and found out that not all kidney-shaped covers are the same. Son of a
bitch! Apparently, the L5S cover is larger than normal because the control cavity is larger than normal because Gibson used to put 429 different pots and switches in there. Iceholes.
So, I did it all over again, this time with the cover that came with the body as a template. End result...
Whew!
In retrospect, I probably should have stuck with the black cover on the control cavity, and made a black switch cover. The cream matches the binding, but the black wouldn't have stood out so much.