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You're all wrong. So wrong.
Could you go for an extended junior style scrath plate. Minimise the amount of coverage?
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Quick update, and a huge thanks to @m_c who managed to interpret my slightly odd measurements and even odder drawings into sense, and manufactured the aluminium scratchplate.
The wiring is all done (though whether it's done correctly or not is yet to be proven!) , all hidden beneath the 'plate.
So, jobs;
Undecided whether to leave the top right corner of the 'plate as-is, or whether to try smoothing the corner a bit. Also will add a slight chamfer to the top edge of the 'plate as it's a little sharp.
Evolution, schmevolution. It's only a theory.
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Glad it fits as planned. I very nearly put a chamfer on the top edge, however I've not got any chamfer bits set up in the software I was using, so never bothered.
If you've got a suitable router and bit, wood bits will work on aluminium, although you may need to screw it to a bit wood, use the alu as a guide to cut the wood to shape, and then use the wood as a guide for putting the chamfer on. Other options are a deburring tool (takes a bit practise to get consistent), or sander.
Love that scratchplate @m_c ! I've added you to my list of 'people it could be useful to know'
I ended up using a file to put the chamfer on the edge and then worked through the grades of sandpaper to smooth out the filing marks. Happy with the result, but ...
I then needed to remove the scratches in the top. So, again worked through the grades of sandpaper, and then thought that I'd 0000 wire-wool the top before polishing it. Turns out that was another mistake as aluminium doesn't seem to respond well to wire wool. It ended up "blotchy".
Back through the sandpaper grades from 180 to 1200. Then polished it with the wire wool kept at a safe distance.
Next time perhaps I should just buy a standard plastic scratchplate ...
Set-up (nut & intonation) still to do.
You can play your own bloody bass at Fretboard Jams now
Nil Satis Nisi Optimum
Feels good to play as-is, but the action will be improved once I've done the nut, and it'll sound a lot better when I've done the intonation too.
Overall, happy.
As alu is soft, it can choke media very quickly, and also get contamination engrained, so the wire wool very likely choked causing the plate to gall, which led to the blotchiness. Putting a bit lubricant (WD40 would do) on the plate/wire wool would of stopped it galling, and allowed the surface to be burnished by the wire wool.
The finished article does look very nice though.