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Blank pickguard material + cutting methods?

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poodlesrule

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I am getting a Rondo white Strat as a modder, and would like to try my hands at making an interesting pickguard, and have a few questions:

- good source for "traditional" blank material (pattern may be non-standard)?

- other suitable material? Formica, thin wood veneer, etc..?!?

- photo effect on original white pg? (I pm'd tremoloman about his work, the yellow Tele)

Cutting the material clean and without cracks may be a challenge, depending on the material... (drill holes before cutting outline?).

I have to say my choices would be a nice cherry, or rich Paisley pattern! I bet one could carefully build a lexan or plexi sandwich, with the fabric as middle layer... and with fabric, the sky is the limit (spouse is a quilter, and boy, do we have fabric..!!)
 
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I've made my own pickguards in the past, but my method is a little complicated and takes a few tools.

To copy an existing pickguard, I use the original as a pattern. I make a spacer to go between the original pickguard and the blank material. I use cheap 1/4" plywood, trace the orignal pickguard's outline onto it and cut out inside the line with a jig saw. Next using double sided carpet tape, I attach the original to the spacer and and then put it on top of the blank.

To cout away the waste, I use a collar and a 1/4" straight bit in a laminate trimmer with an offset base. This removes most of the material for the next step. Finally, I use a table mounted router and a flush cutting bit to cut the blank to its final size.

For cutting out pickup holes, I've made several templates using 1/2" thick clear Lexan. You can also buy these at Stew-Mac.

For the screw holes, I use a drill press to bore out the holes and a counter sink bit to countersink the holes for the oval screws that attach the pickguard to the body.

Routing plastic is messy: it throws little chips all over the place. Also, plastics like Lexan and acrylic are brittle. I've had a few pickguards ripped out of my hands and ruined by the router bit.

Routing is dangerous, it scares the hell out of me and I've been using routers for 15 years or so.

The best place I've found to buy blanks is Warmoth Guitars.

You can always try your local plastics retailer. Sometimes they have a scrap bin. Most of the sheet plastics I've seen are on the thick side: .125". Most pickguards are between .060" and .100" thick.

tung


poodlesrule said:
I am getting a Rondo white Strat as a modder, and would like to try my hands at making an interesting pickguard, and have a few questions:

- good source for "traditional" blank material (pattern may be non-standard)?

- other suitable material? Formica, thin wood veneer, etc..?!?

- photo effect on original white pg? (I pm'd tremoloman about his work, the yellow Tele)

Cutting the material clean and without cracks may be a challenge, depending on the material... (drill holes before cutting outline?).

I have to say my choices would be a nice cherry, or rich Paisley pattern! I bet one could carefully build a lexan or plexi sandwich, with the fabric as middle layer... and with fabric, the sky is the limit (spouse is a quilter, and boy, do we have fabric..!!)
Click to expand...
 
look up a local plastics supplier , they will have whatever you want as far as lexan. a good choice by the way(don't try to cut or drill thin acylic.)
it comes in very thin sheets and they will cut it to size for you for a couple extra bucks.
 
Keep in mind that some pickguard material is highly flammable, especially the stuff used on vintage instruments or sold as "vintage spec" for repairs. The newer plastics are safer, but you still have to watch for heat build up due to friction while you work. I've cause a bit of melting here and there with routers, sanders and drill bits.

One local guitar repairman told me he's had any number of vintage-type pickguards burst into flames as he works on them. I'll bet that can ruin your whole day!

Have fun...and be careful out there, kids!
 
Good suggestions so far!

Image transfer methods look promising - that could get me that paisley or fractal image I seek...

Thin wood veneers could work, with possibly a bottom aluminum sheet for strength?
 
Here a couple of examples of unusual and cheap materials I've used:

1.) Painted Masonite
thumbrest_02.jpg


2.) Vinyl floor tile
marblepg_01.jpg
 
tunghaichuan said:
I've made my own pickguards in the past, but my method is a little complicated and takes a few tools.

...

Routing plastic is messy: it throws little chips all over the place. Also, plastics like Lexan and acrylic are brittle. I've had a few pickguards ripped out of my hands and ruined by the router bit.

...

tung
Click to expand...


Cutting Lexan is fairly easy using a low tech approach -- i.e. an X-acto knife with a NEW blade. Just score the Lexan using a single stroke by pulling the blade along with light pressure and rotating the handle between the fingers to "steer" the blade along a pre-drawn guide line (a Sharpie pen works well to make the guide line).

After scoring around the shape, make radial cuts from the outside of the Lexan sheet to the scored cut. The amount of these cuts you need to make depends on the radius of the curve of the shape that you are wanting. The smaller the radius, the more of these "hinge" cuts you need.

Once you make the radial cuts, simply bend the Lexan away from the score mark and it should break very cleanly along the line.

I've done this using the convoluted shapes of 1/10 scale RC Lexan model car bodies. With a little care and a sharp new blade, I've cut scrolling curves with less than an inch radius -- both inside and outside curves. A big ol' flat piece of Lexan would be cake.
 

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