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i used to hate making plates. now I always put the time into making a decent template first and making the plates takes a few minutes.
i do sometimes hand scrape a bevel, but even that is easier with a decent template providing support underneath
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A mate of mine had some pick guard material left from a LPJ build of his and he made me a Junior styled guard for the SG. I think he used the Dremil (as he did for most things in those days).
https://www.dropbox.com/s/5t1vp8rkdou10te/IMG_9916.JPG?raw=1
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For me the time consuming part is making the template, but that can be very dependent on what sort of workshop equipment you have - very limited at Chez CasperCaster. Anyway, better to screw up with a piece of ply or MDF whilst making the template than a sheet of pickguard material. And the time is obviously less of an issue if you intend to make multiple pickguards.
If you have an existing pickguard you can copy, then that obviously helps, but you generally need to tape multiple pickguards together, and tape the edge if you want to avoid having the router bearing eat into the existing pickguard.
Doing a Strat style switch slot can be tricky. I used my Dremel in a router base, and cut the slot with a small down-cut inlay bit, and set up a fence to push the Dremel along. It worked for me, but there are probably more effective/efficient ways to achieve it.
There was a thread about cutting acrylic pickguards, probably about a year ago - can't find it now unfortunately. Anyway, one thing I took from that thread was that there is more than one type of acrylic. Apparently it can be made into sheets by different processes, and the cast type is less brittle and more forgiving for cutting and routing into pickguards. If I ever get around to finishing my Paisley build I'll let folks know how I get on.
http://www.thefretboard.co.uk/discussion/89942/caspercaster#latest
http://www.thefretboard.co.uk/discussion/97209/cutting-out-a-pickguard-advice-please#latest
http://www.thefretboard.co.uk/discussion/89942/caspercaster#latest