Why is it sometimes...

[Tim Benware]

one just goes brain dead? I was cutting the channels on my latest build and the rosette thickness was .100", top was at .110" so I wanted to cut the channel a little under .100" and yes I went the other way and cut right through the sound board. Now I have a 4.5" sound hole. Well I was gonna to build a Clarence White/Tony Rice type dred so I guess this is it!!

[Kevin in California]

Yikes, too bad, but hey you may find that the guitar sounds alot better with the bigger hole.
On a dred it probably won't be that noticeable. Use a narrow rosette close to the hole for a better perspective.

[Dave Bagwill]

You could also bind the soundhole to decrease the diameter a bit.

As to why it happens - old age. Hahahahah

[John Parchem]

Dave beat me too it ... but
I fixed one of those once. It was on a ukulele so I thought I had a bit of latitude and my fix did change the design a bit. I made a sound hole reinforcement batch and glued it onto the back of the top I accurately found the center of the rosette and drilled a hole through the patch for the router pin. I made a rosette thats inside hole was the size of the sound hole. I routed the outside diameter of the rosette at the depth that took it to the patch and inlayed the rosette on the patch and used black fiber to purfling inside of the sound hole. It turned out OK almost like I planned it. It was a really special top, otherwise I would have started over.

[Tim Benware]

Good suggestions. I had already decided to just use the extra large sound hole, it will be interesting to find out if I can hear any difference. Here's what it looks like.

[Herman]

You do fine Tim,

On my "Jumbo for loud settings" I made a soundhole of 4,5 inch. That to prevent a booming sound when played in a band. Well, it is one of my best sounding guitars. Everyone who played it, agreed it is a hell of a guitar. So do not panic. Later on you will be pleased IMO.
http://hermanarendsenguitars.nl/loudjumbo.html

Herman

[Tim Benware]

You do fine Tim,

On my "Jumbo for loud settings" I made a soundhole of 4,5 inch. That to prevent a booming sound when played in a band. Well, it is one of my best sounding guitars. Everyone who played it, agreed it is a hell of a guitar. So do not panic. Later on you will be pleased IMO.
http://hermanarendsenguitars.nl/loudjumbo.html

Herman

Yes, I'm actually looking forward to even though I hadn't planned it for this one.