thanks for your feedback on this. thought you might be interested to know that I've been working to address the sizing topic since my last post
undrilled pickup covers continue to be difficult to source without going the custom injection molded route. there are a couple undrilled plastic covers available, but they are very square and shiny. definitely not something I'd want to use as a long-term solution
I've been working on the workflows for epoxy casting pickups similar to what you would get when using a Bartolini pickup (not the pickup coil, just the casing) The first step was learning how to create a clean silicone mold
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TintedEpoxyTestPour_1.png [ 382.32 KiB | Viewed 26930 times ]
The second step was finding the right epoxy that cured solid without a lot of thermal buildup (to protect the coils) and that also tinted well without any significant loss of mechanical properties. Based on my testing so far, I believe I now have the right epoxy resin/hardener and tinting medium for a consistently black encapsulated pickup. Here's a peek at a test pour of the encapsulating material we'll be using as it appears freshly plucked from the mold
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TintedEpoxyTestPour_1_FreshFromTheMold.png [ 351.09 KiB | Viewed 26930 times ]
There's still some detailing to be done to the final finish. With this method of encapsulating the pickup coil, I'll soon be able to offer pickups in sizes that are impossible to find covers for as well as custom sizes and designs for those wishing to step out of the norm
More to come in a follow-on post, including an image of a fully encapsulated coil ready for installation