Low Output P90s

That thing is just gorgeous, and I love the wraparound setup. I would be playing that thing constantly!

For frets, you might want to do some research to figure out if Dunlop 6250/6270 is available in stainless. It's the closest you'll get to a direct fretless wonder fret these days. It's .005" wider, and about the same higher than fretless wonders were when new.

That said, 6230s definitely are available in stainless, and if you were to actually mill them down to the correct dimensions, you'd get a more accurate repro of the fretless wonder frets. This is because they start out wider and taller than 6250/6270. Fretless wonder frets have very straight sides and no crown across the top. Their profile was rectangular, basically. The "corners" were slightly softened, and that's it. If you are starting from a fret that is .078 by .042, you have more meat to allow you to shape them into the correct rectangular profile, compared to 6250/6270, which have to low a crown to allow that.

Instead of modifying the original retaining sheet, have you considered purchasing a modern equivalent, and setting the original aside? You can get most P90 parts at Mojo-Tone Music. Here's the part in question for $2.50. https://www.mojotone.com/guitar-part...el-Silver-50mm

If you want more oomph from the pickup, A3 is probably going the wrong direction. I would consider A4, A5, or UOA5.
 
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Sorry, I meant the keeper bar. I'm not able to screw in the wide flat screws to keep the baseplate and bobbin together. I purchased a throbak baseplate, the original is safe and sound.
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NOS A3 magnets arrived. Wow, what a difference quality magnets can make. I was ready to give up on this pickup, but the magnets proved to be a saving grace. P90 has a more lively and assertive voice. Similar to the bridge up despite the DCR. I actually may have to lower it a bit, but its matching the output from bridge.

Night and day difference. The magnets that came with the p90 were for sure not original. If I had to guess, they aren't properly charged and the size difference may have made an impact.

I've also changed some hardware to include the bridge studs and stoptail. The guitar is really opening up and chords sound better to me. Feels like I took a blanket off the les paul. Sounds what you would expect a good old guitar to sound like. The refret should take playability to the next level as well. Can't believe I thought this guitar needed a humbucker lol. Not a chance.
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It is strange how magnet swaps can make such a big difference on some winds (this example above, or a Custom 5) and not so much in others (JB). But experimentation certainly pays off.
 
Amen to that. I'm glad that experimenting allowed me to do this myself. I'm saving so much money rather than spending $350-550 for a vintage p90 from 1952-53. This is also a good example of DCR not meaning everything. Let your ears decide what sounds good and doesn't.

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When I bought my 50's p90 set+harness I sent them off to James at Rewind. He determined that amongst other things, the (in my case, original) magnets were severely discharged.....such that 1 mag had almost no charge left.
Its an 'occupational hazard' of buying old p90's..........you really do need to look out for the magnets. Its like filter caps and old amps.
 
I haven't thought about it that way AlexR, but that's a good point. Will keep that in mind moving forward.

Speaking of James at Rewind Electric, I actually just received my '50 Lap Steel Pickup. It went in for a repair and conversion. The pots/cap were turned into a tele harness. Killer work as always. I have 3 pots (2x 500k and 1 250k) dating to 1953 for this les paul. I'm going to send this in for a harness once I find another 500k pot.
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