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Making My First Lap Steel

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The lap steel I am currently making is the first time I have ever tried to make a guitar. I am making it completely from scratch without any tutorial books, so I am relying on luthiers via the internet to answer the numerous problems I hit. I am very grateful for any help anyone can offer.

My current problem is the input jack. My lap steel is a rough Weissenborn shape, so very curved, and I want the input jack to go on the side of the guitar. However the wood from the electronics cavity to the side of the guitar is very thick, so the input jack I have can't fit through. I thought about routing a little groove in the side of the guitar to make it less thick, but I'm not sure this would work as I have no flat surface (the side of the guitar is curved) to rout on. Aswell as this, I'm not sure how to drill the hole at a perfect 90 deg. angle. Would a hand drill be accurate enough. If you know what I mean, then what is the best solution to me problem?

I have made a diagram to make the problem easier to understand, but I don't know how to attach it to this post. If anyone knows how then tell me and I'll do it.

Thanks a lot, Ben

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i've made quite a few lap steels and i think i understand you problem but the diagram would help. can you attach it to a pm to me? if you can do that i'll take a look and see if we can come up with a solution.

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