The binding that I got was larger that the notch that I routed. I hoped that once glued, the plastic could be worked the same as the wood. That went very well. I used a belt sander to shape the edge and a random-orbit sander on the top (then finished with files and sandpaper by hand). It wound up being a nice smooth surface between the wood and plastic. Even drilling the jack hole felt like going into a solid piece of material.
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Filling the edge gaps with epoxy ▸
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