Enlarging the truss rod notch in a precison 4ply plate

[Twigman]

I am fed up of having to take the plate off to tweak the truss rod.

What's the safest way to enlarge the truss rod notch on a 4 ply pickguard so it won't need removing whenever the rod needs a tweak?

By safe I mean it will look neat and symmetrical and making the mod won't split the guard.

[Muppet]

I've done this a couple of times - a fine half moon file does the job. Mask off the area around in case of slips. If you want to be extra picky, follow that up with wet and dry paper wrapped around a piece of dowel.

[DarkHeart]

get a dremel or the cheap equivalent from lidl or aldi for about 15 quid and away you go.

[JPJ]

[quote name='DarkHeart' timestamp='1446221141' post='2897897']
get a dremel or the cheap equivalent from lidl or aldi for about 15 quid and away you go.
[/quote]

Be careful with this method, it works, but if you run the tool too quickly you will melt the pickguard rather than remove the material. Junior hacksaw and a good round or half round file is your best bet.

[PlungerModerno]

[quote name='JPJ' timestamp='1446229078' post='2897999']
Be careful with this method, it works, but if you run the tool too quickly you will melt the pickguard rather than remove the material. Junior hacksaw and a good round or half round file is your best bet.
[/quote]

+1. A sharp kinife can also be used, but only if you're good with one. Plastic is tricky sometimes (can chip or crack). Best to use a file or a sharp saw hack saw with light pressure to avoid damage to the plastic.
If you have / get a dremel tool or other mini multi-tool - remember they are a speed not a torque tool. It can do a lot, but very little at a time. Go slow, mark your lines, work your way up to them (that applies to hand tools or power tools equally to be honest).

[Norris]

Depending how much material you need to remove, I'd stick to hand tools - probably a file. Power tools can remove a lot of material very quickly, sometimes too quickly.

[MoonBassAlpha]

I've used a coarse round file and finished with a half-round needle file. You should be able to get as good a finish as anywhere else on the plate using this method.