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That's what I would do, I'm not sure if you can avoid the pop entirely if you're applying power at the same time as the effect is being engaged. Fuzz Faces have a tiny current draw so as long as you disconnect the input when not using the guitar the battery should last ages.

Yes ragamuffin, you have the location of the small resistor right. The 25uF value of that cap is important, dropping it down to 1uF would make a large difference in sound. That cap bypasses the emitter resistor to maximize gain, and for signals of high enough frequency the impedance of the...

You don't actually need a pulldown on the output here. If the volume pot comes after the output cap like that, it functions like an output pulldown resistor itself. And example where you would need an output pulldown is on something like the Rangemaster where the cap comes after the volume...

A jeweler's saw can be a good way to get a fairly even cut without needing to sand the edges down after, although it's hard to beat the sanding method for smoothness. When I've sanded the edges, I use adhesive-backed sandpaper and stick it to a flat surface and then run the board across it.

The poles in a DPDT relay get switched together just like if you had a DPDT toggle switch, so you can't use one relay and switch each pole separately like that unfortunately. It could be accomplished with one microcontroller controlling two SPDT relays (or DPDT relays and just using one of the...

In this case it would probably be best to track down an actual log 5k pot, but there are some tweaks you can make to get close to what you're looking for without one. The 5kΩ of the pot in series with 5.1kΩ of R5 are important for biasing of the transistor here, so unfortunately it's one of the...