Modify Humbucker Openings Or New Pickups?

[Steve Mavronis]

I'm in a dilemma. The Tonerider Birmingham humbucker pickups I bought for my Harley Benton TE-20 HH SBK are too large to fit through the pickguard and bridge plate openings. Here are some measurements I took with calipers:

Pickguard pickup opening - 69mm x 36.5mm
Bridge plate opening - 69mm x 37.5mm

[Guyker pickup mounting frame just as "normal" opening size reference - 71.49mm x 39.69mm]

Tonerider Birmingham - 70mm x 37.5mm
(overwound coils bulge past bobbins) also their mounting screws are smaller diameter but luckily the heads are large enough. I may look for mini washers or hole inserts.

So, I either get different pickups (trial and error to see what fits) or carefully file open both pickup openings which will come very close to the adjustment screw holes.

Any other mod related ideas? Smaller tele bridge with separate metal pickup rings and add screw mounting blocks to the pickup cavities?

Makes me wonder if I should have just gotten the cheaper Fleor Alnico 5 humbuckers but Tonerider was the better quality choice.

 

[TomBrokaw]

Personally I'd try filing to fit. If it works, you're good, and if not, then you'll need to replace parts anyway.

 

[Steve Mavronis]

Yeah leaning that way. This is a guitar mod project anyway. Lucky I have steady hands and sharp eyes from my artistic days. It seems the openings are under sized anyways. Originally I was thinking about black covered pickups but got "regular" humbuckers to avoid that LOL karma. I guess those Guyker metal frame opening specs are "normal" to fit covered humbuckers maybe? Thinking of using those dimensions as a guide when filing to enlarge both openings.

 

[effzee]

It's a Harley Benton, a guitar that was practically born to be modified and experimented on. They enjoy it! Start filing

 

[kuch]

Is there any chance that the new pickups would fit in the old pickup covers?
Or maybe it would work without the covers.

 

[bobio]

Really just depends on whether you have a problem with a permanent modification.
I have guitars that I won't do anything that can't be easily reversed and others I don't mind modifying.

Working on a project right now with a Fender Classic 60s replacement body with a traditional single coil neck pickup cavity.
I am going to be routing the neck pickup cavity to be able to accommodate a P90, a humbucker or single coils.
Gonna make a template using a Stewmac P90 template to get the side to side width to fit a P90, then I will move the template slightly on a second pass to get the front to back depth of a humbucker. Once I get my template right, that is what I will use on the body.

I have multiple routers that would do the job, but Santa just brought me a new toy that I am going to use on this project

 

[Steve Mavronis]

I don’t mind modifying my guitars. I already replaced the tuners and string trees and nut that I will “Elmer” on after checking action when it’s stringed up. Had to do a minor repair when I accidentally popped out a half circle on the finish at one of the slot ends. Not sure what to do about the finish since too much fine sanding may detract from the satin matte black finish. Before and after photos.

 

[Steve Mavronis]

Is there any chance that the new pickups would fit in the old pickup covers?
Or maybe it would work without the covers.

There were no old pickup covers. The stock pickups were uncovered humbuckers with fake adjustment screws. I was thinking about getting covered pickups but knew that would require enlarging the holes to accommodate.

 

[robt57]

So, I either get different pickups (trial and error to see what fits)

What happens when what fits doesn't come close to sounding or have the response for what you use this hammer for.

Get the right pickups by response, make them fit. What good is a hammer that the claw won;t pull nails out???

JUST IMO...

Nothing wrong with it, if your priority is how it looks modded, follow that path. Else if how good use it will have modded plugged in, easy decision.

I've seen pretty bastardized nice 60s Teles that sounded killer.

I say think El Kabong.

 

[Steve Mavronis]

Yeah I agree. I'll just continue with the mods.... they are fun anyway. Just anxious to get this done after the holiday.

 

[eallen]

Dremel with drum sander or bur on it. Done in minutes.

 

[Steve Mavronis]

What are hole size guidelines (mm) for humbuckers and covered humbuckers just in case I ever switch to them. I think normally a hole should be like 70.5mm x 38mm (at least that's what FLEOR 8 Hole Tele Pickguard humbucker hole size is when I searched for a reference idea) but for larger pickups with covers you may need more space? Is there a universal magic number to cover my bases?

So basically I'll mask off the desired edges with painters tape and enlarge the bridge plate edges by 1mm and file the pickguard hole to match and double check the pickup fit.

 

[TX_Slinger]

Interesting since my Tonerider Birmingam set seemed to be too tight for the H-slot humbucker covers (but I forced them in anyway). They fit through the opening in the standard pickup rings I used though.

 

[robt57]

Interesting since my Tonerider Birmingam set seemed to be too tight for the H-slot humbucker covers (but I forced them in anyway). They fit through the opening in the standard pickup rings I used though.

Problem being if the PU isn't floating freely as designed to be, you'll have problems with micro-phonics and feedback etc, likey to anyway...

If any part of the cover or baseplate is touching wood, especially thru a hot front end of an amp you will likely not be a happy camper... Even too tight in the ring will have ramifications..

 

[Steve Mavronis]

I found these from archived Warmoth image search results. I emailed them too waiting to see what they say they use for their pickguard dimensions if they've changed over the years. I’ll probably use the more squared off larger height and width, maybe slightly bigger to leave some wiggle room, since my (uncovered) Tonerider Birmingham pickups seem about 70mm (neck) to 70.25mm (bridge) wide with the overwound coils. I'll use the smaller radius corners for the bridge plate but fat radius for the pickguard.

 

[robt57]

The fat is for uncovered HBs, you need square corners with the covers and EMG actives etc.

 

[Steve Mavronis]

The fat is for uncovered HBs, you need square corners with the covers and EMG actives etc.

Yes I know the terms.... the Tele bridge plate that I have to expand has squarer corners so I can't make them "fat" if I wanted to.

 

[robt57]

Yes I know the terms.... the Tele bridge plate that I have to expand has squarer corners so I can't make them "fat" if I wanted to.

You should need to. A uncovered PU should fit in a non fat opening with room to spare I'd say. If the conversation is about fitting...

 

[Steve Mavronis]

You should need to. A uncovered PU should fit in a non fat opening with room to spare I'd say. If the conversation is about fitting...

That's correct, except the humbucker set I got is slightly wider than both pickup holes allow! The stock guitar body looks like this with the original cheap quality OEM no-name brand that I am replacing with slightly overwound Tonerider Birmingham pickups which have wider coils than the bobbins size and won't fit without modding.

 

[robt57]

Wrong pole spacing as well??? google F spacing and non.