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http://www.thefretboard.co.uk/discussion/89942/caspercaster#latest
It's slow and very, very dull without a router, but manageable. Depending what yr making it from but for similar I've lightly sprayed white paint and scored onto that to give outlines, marked drill holes with a pointer. The white will wipe off easily later with celly - with ABS & similar - some materials won't like it.
Cut somewhere outside the line. Get a bit closer with a bench grinder or disc sander. Then to the line with files, sandpaper, blades.
Bevel with Stanley blade or scalpel, polish edges.
Drill & countersink.
Pickup cutouts are the hardest to get neat esp single coils where anything slightly off, looks really off.
If you've got a router I'd use that every time.
TLDR - Jacks or similar is a load less faff..
is it crazy how saying sentences backwards creates backwards sentences saying how crazy it is?