G-400 Rewire Issue. Help?

LoFiBrian

LoFiBrian

New member
So I have here from Specialty Guitars:

4x CTS 500k Audio Taper Split Shaft Pots
2x Mallory 150 630v .022 Caps
1x Switchcraft Switch With Cream SAE Tip
1x Switchcraft 1/4" Mono Jack
+ A Few Feet Of Wire and Some Shielding Adhesive Tape

Ohh Boy going to start making up a harness for my SG right? Can't wait to try out the C5 in there!

Step one...Make sure the shafts of all the parts fit the import body. Good Start before I get too far. The Switch is a direct fit and quite a upgrade over stock. kinbda messed with it a little bit and got kinda toggle happy.

Then comes the CTS pots? they umm dont fit the stock holes for the old Alpha 500K's

Seems based on my handy hole size guide thingy i found in a tool bin:
the alphas are: 5/16's
the CTSs are: 3/8's

My guess is the holes are somewhere in between the 2: 9mm's / 23/64ths?

The same goes for the Output Jack too!


What am I going to do to get them to fit and not fudge up my guitar?

Ideas? Help?

-Brian
 
Re: G-400 Rewire Issue. Help?

It's happened a few times to me. I just drill the old holes a little larger with a bigger bit. Drill from the top of the guitar, carefully, and any chips or splinters should be inside the cavity where they won't show.

Have you done any re-wiring before? Sounds like you're enjoying it. Always fun to upgrade an Epi. I've done many. If the C5 is a little bright, which it is for me, but I like warm guitars, you can use either a 250K pot or two, or an A4 magnet. But try it out & see what you think first.

Keep us posted.
 
Re: G-400 Rewire Issue. Help?

Drill 'em out!

Most import guitars have different size holes then USA's... not uncommon that CTS & Switchcraft won't fit... though, the Switchcraft toggle I put in my ESP fit just fine. I can't recall having to drill for the pots either and they're CTS... I pulled out EMG's.
 
Re: G-400 Rewire Issue. Help?

I'm not handy with a drill...I'm afraid i would screw it all up.

the difference is less than a millimeter...

I supose I could maybe sand them or dremel them carefully?
 
Re: G-400 Rewire Issue. Help?

LoFiBrian said:
I'm not handy with a drill...I'm afraid i would screw it all up.

the difference is less than a millimeter...

I supose I could maybe sand them or dremel them carefully?
Click to expand...

I prefer to drill, slowly & carefully. Do what you want, but drilling keeps the holes round & doesn't chew up the wood. Remember that top is very thin at the control cavity.

We'll be waiting to hear back from you. And don't forget to relax & have fun.
 
Re: G-400 Rewire Issue. Help?

Buy a tapered reamer. That's the answer hands down. It's perhaps the best tool purchase I've EVER made, and that was 15 years ago. In this situation, it's the "can't fail" device.
 
Re: G-400 Rewire Issue. Help?

Yes but no. Those are specially profiled and cost way too much. Standard reamers are $5-$20 at the hardware store. More like this:
T-Handle reamer
Mine has a screwdriver handle and I think was even less. Since we're just reaming wood, and usually it's thin holes, etc. you can buy literally the cheapest reamer you can find and it will be fine for this stuff.
 
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Re: G-400 Rewire Issue. Help?

I used a BRAND NEW general purpose bit to drill my G-400's output jack hole, to fit a large toggle switch. It worked flawlessly. I think it cost $8-$11. Old drill bits (the first time they are used on steel) are far less sharp. It was drilled from the top of the guitar.

I would add however that that I put two pieces of masking tape (perpendicular to each other) over the hole to reduce the possibility of paint chipping. The tape was pressed firmly against the body, and carefully removed.

Bottom line, a reamer is safer but one does what one must at times.
 
Re: G-400 Rewire Issue. Help?

Here is a update on this for you guys who helped me.

I decided after some thought to have my best friend contact his tech friend. He used to work in a local shop and did some of the best wiring I have ever seen. He got ahold of him and got the holes reemed and the wiring done for a flat $20. His work is perfect and I could not be happier!

Well here is the run down:

2003 Epiphone G-400 Vintage in Worn Cherry

She is perfectly intonated and setup with D'addario EXL110's.
Fret Dress and Bone Nut by Frank Falbo.
Stock Grover 18:1 Chrome Tuners.
Gotoh Chrome Tailpiece & Tone Pros Metic Chrome Bridge.
Nickel Jazz Neck and Custom Five Pickups
Switchcraft Switch And Jack.
CTS 500k Audio Taper Pots with Vintage Style Nickel Knob Pointers.
Hovland Caps - .015 Neck and .022 Bridge.
Dunlop 360 Nickel Strap Locks.

It plays like a dream and I have no complaints! This should keep me out of Real Deal Gibson SG GAS til I can put the funds away.

-Brian
 
Re: G-400 Rewire Issue. Help?

SG2.jpg

SG1.jpg

SG3.jpg
 
Re: G-400 Rewire Issue. Help?

Nice!!!

I'm really happy with my G-400. If you get a couple extra coins jingling in your pockets, I think black screws for the pickguard/truss rod cover (and pickup rings) would add a really nice clean look.
 
Re: G-400 Rewire Issue. Help?

yeah i've been tempted to do the PU ring screws and neck joint cover plate screws in black to look more like a real deal 62'. And order fresh screws for the rest of the guitar. Maybe next time I order something a little bigger.
 
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