I had purchased a 25/64th drill bit to enlarge the tuner holes on the headstock to the perfect size, but I felt very nervous about drilling. What if I wasn’t lined up properly? What if I took a big chunk of wood out of the headstock? What if the tuners still didn’t work?
Thanks in part to a comment on my last post, I went to one of my local guitar shops and, after explaining my situation, they suggested using their reamers. They had two sizes, so I started with the small one and then went to the larger one.
I’ve used a reamer before, and this just confirmed how easy it is…especially for existing tuning machine holes. I went very slowly and continually checked the size against the tuners and the tuner bolt. I reamed the top and bottom and then based on Dan Erlewine’s book, used a round file to flatten out the center of the hole (since reaming the top and bottom leaves a little hump in the middle).
More pictures to come!