So the jack recess is done.

I started using a hole bore drill bit, handheld. Didn't really trust that thing running at high speed without a centre guide.

Click image for larger version. 

Name:	bore_hole-IMG_2612.jpg 
Views:	780 
Size:	27.8 KB 
ID:	2629

Then using the dremel to level out the recessed area, sandpaper to round the corners, I ended up with a recessed jack I'm fairly happy with.

Click image for larger version. 

Name:	recessed_jack-IMG_2614.JPG 
Views:	800 
Size:	74.4 KB 
ID:	2630

View from the front of the body:
Click image for larger version. 

Name:	recessed_jack_face_on-IMG_2616.JPG 
Views:	793 
Size:	64.0 KB 
ID:	2631