Hey JT here's a few answers to your questions:
1. When you talk about switching the pods, do the TV Jones come with a all new wiring, or do I have to order a new wiring harness as well?
The pickups do not come with a new wiring harness. There's no need to order a new wiring harness though (unless you want 5 to 10% better fidelity). If you order a new wiring harness and want to keep your current knobs, be sure to order a "split-shaft" harness. If you want the American-style 1/4" solid-shaft harness, you'll need new Gretsch knobs. Also if you order a new wiring harness you'll need new switch tips (whether you go with solid or split-shaft pots). TV would recommend you save your money unless your current pots are crackling etc.
2. You mentioned filling the holes with tooth picks and glue and color matching. Are these holes hidden under the new clear cover or are they exposed?
They would be hidden (except for the fact that the rings are clear) Why not go with silver rings (like a 6120)? Then the holes would be hidden for sure, plus your guitar would look more like a 6120. (by the way all Gretsch guitars, orange or otherwise, with chrome hardware, have silver rings
3. Did you have to shave the side of the pick-up hole for it to align properly under the strings?
Shouldn't have to.
4. Was it hard to re-secure the wiring harness once you fished it through the guitar again?
Shouldn't be hard
5. Did you have to replace or remove any wood shims?
Wood shims are only an issue with Fender-made pro-line Gretsch guitars. The 5120 has traditional humbucker cavities.
6. When you finish mounting is the plastic ring attached to the top of the guitar or is it sitting on the black blocks that are currently on the Gretsch pickups? I have a concern that the pick-up will be way too low with the EM2 mounts? Could you please explain the difference of what is currently there vs what the TV Classic would have?
The EM2 English Mount Kit comes complete. You will not need the black blocks. The kit is self-contained and the new pickup is attached to the ring. The kit pops right into your existing 5120 cavity and the ring screws into your guitar top (see photo)
