When replacement parts aren't...

If there is not much material to remove, a tapered reamer would work best on plastic. Careful sanding with the small drum sanding wheel and a Dremel would work too. How much are you talking about removing?

 

If it were me I'd just enlarge the holes. It won't hurt anything or affect resale value. As suggested do it carefully so its a clean and invisible mod. The other option would be to source the proper value pots with smaller shafts.

 

The Tribute series probably used import pots back then which have smaller shafts. The ones you ordered from G&L are probably better quality parts used on their US instruments, so it's worth reaming your pickguard holes to 3/8" to accept the "full size" pots. You can get a tapered hand reamer from Harbor Freight for about 3 dollars.

 

Another vote for reaming the holes to fit the SAE-sized pots in there!

Memo Romero was quite helpful when I called about the controls-cover & missing knob on an L-2000.
However, in this particular case I think you have better-quality parts than the originals.

 

Either the next largest drill bit, a rod-file (not sure the correct name) or a step drill-bit. Easy peezy.

 

Tapered Reamer

Best $2 you will ever spend.

T-Handle Reamer

 

Wood, plastic, metal, the tapered reamer is your friend

 

The only thing I would add is applying scotch tape over the holes to keep edge splintering under control while widening.

 

Yep the reamer is your friend, I recently got one at Harbor Freight for under $10.
And it's the best safest way to do it, and yeah better pots are worth the effort.

Good luck,
Dirk

 

A step bit for me is the safest way to incrementally open up a hole on a body or pg. Each 'step' is just slightly bigger and it makes a clean hole. I have two that cover most needs.

 

reamers and step bits are the bomb, IME, but for this situation, you could easily use your own drill bits: the idea is to not drill holes which are too big. good luck with your pickguard holes!

 

The reason we never use a Twist Drill to enlarge holes in wood, is that depending on the grain direction, the bit usually lifts up and tears out the wood

Every luthier gets at least 2 of these a month, "Ummm, I'm so embarassed...can you fix this?" :



Also, Twist Drills will often favor one side of the hole, causing unevenness in a line of holes.

 

I have a rat tail file that will do the job; but at this price I'd spend the money and use the reamer. They really do a neater job than anything else mentioned thus far.

 

The important thing using a drill press is making sure it's centered and clamped down. Once that's done, if your bit is sharp - fast speed and quick - boom, done.