Make your own pickguard

[MadAsAHatter]

I while back I wrote up a guide for making a replacement pickguard from an old one. I came across it again and figured I'd share it here.

How to make your own pickguard.

There are 2 main options for making a pickguard using the old one as a template. Option 1 requires a couple of basic hand tools, sand paper and elbow grease. Option 2 involves power tools and making a plywood template.

Option 1:
Using this option is best for obviously when you have access to minimal tools and are only going to make one or two pickguards. Keep in mind that since you are doing everything by hand the shape will not be as precise, but can still look well made.

Tools needed: coping saw (or similar), drill, drill bit(s) & countersink bit, sandpaper and something that will mark on pickguard material.

1. Trace out the shape of your pickguard, pickup holes & screw holes on your pickguard blank using the original pickguard as your template.
2. Cut out the shape, cut the pickup holes, drill the screw holes.
   1. To cut out pickup holes drill a pilot hole then insert the saw blade though the starter hole.
3. If the screw’s you are using are not flat bottom, use the countersink bit to carve out an indention in the screw holes.
   1. It’s best to do this by hand/don’t use the drill.
4. Sand everything to final shape.
5. Sand a bevel onto the outside edge.

Option 2:
This option is best if you need a 100% exact copy of your original pickguard or plan to do multiple copies of the pickguard. It’s a bit more involved because you need to make a template first, but once you do producing multiple copies is pretty quick.

Tools needed: band saw, router, template bit, 45 degree chamfer bit, drill or drill press, drill bits, countersink bit, double sided tape, masking tape, super glue (optional), router table (optional).

Make the Plywood template:

1. Find a piece of 1/2” to 3/4” plywood slightly larger than your pickguard.
2. Using the original pickguard trace out the template including pickup holes and screw holes.
3. Cut the plywood to the rough shape of your pickguard on the band saw
4. Cover the top of your original pickguard with masking tape to protect it. You can forgo this step if you are throwing away the original pickguard.
5. Attach the original pickguard to your rough cut template. You want the original pickguard to “float” above the plywood template. This is so there is space for the pattern bit’s bearing to ride the edge of the pickguard without hitting the plywood template.
   1. Find some scrap wood that is all the same thickness; 1/8” to 1/4” will do.
   2. Attach the wood to your pickguard using double sided tape or masking tape and superglue trick. Make sure none of the wood shims sit outside of the pickguard area or cover any holes.
   3. Now attach that to the rough cut plywood making sure to line everything up.
   4. Alternatively you can forgo the wood shims if you’re using thick double sided tape and it gives enough space between the pickguard and wood template.
6. Set up your router with the template bit so that the bearing only contacts the edge of your original pickguard and blade only contacts the wood template.
7. Cut the pickguard shape and pickup holes with the router. If you bit is long enough you may be able to get it in one pass. If not do one pass then remove the original pickguard to finish the template.
   1. I found it best to use a shallow pattern bit, do one pass, then remove the original pickguard and finish the template.
   2. Depending on the shape of your pickup holes, you may need to chisel out the corners.
8. Finally drill all the screw holes with the drill press or hand drill.
   1. It’s best to double check the alignment by attaching the original pickguard back to the template. Re-mark the screw holes as needed.

Make the new pickguard:

1. Now that you have a template you can make as many pickguards from it as you like.
2. Cut your pickguard blank to the rough size of your template.
3. Stick the pickguard blank to template with double sided tape or masking tape/superglue.
4. Using the router and pattern bit cut out the shape of the pickguard and pickup holes.
5. Swap the 45 degree chamfer bit into the router and cut the outside bevel.
6. Drill all the screw holes.
7. Now you can remove the pickguard from the template.
8. Drill out the screw holes indentions with the countersink bit.
   1. If you’re using a drill press you can set the depth stop appropriately
   2. If you don’t have a drill press it’s better to carve out the indentions by hand rather than using a hand drill and risk going too deep.
9. Last is to test fit the pickguard and sand any areas that may need some final shaping. This usually needs to be done for more squared corners of pickup holes and maybe around the neck pocket.

A couple of additional notes

• If you plan to change the pickup configuration you can forgo cutting out those holes and freehand them on your pickguard.
• When making the wood template in option 2, you can cut out a large rectangle where the pickups would be and make insets with different pickup configurations.
• Don't forget to shield the underside of your pickguard. you can use shielding paint, shielding tape, or aluminum foil and glue.
• If you don't know about the masking tape and super glue trick: you put masking tape on each piece, put super glue on the tape then stick the pieces together. It holds while you work an can be pulled apart when your done without leaving residue. There's several videos and instructions out there for more detail.
• As always, take your time and triple check measurements and alignments as you are working.

Here is a before and after example I did using option 2. The original is on top and replacement on bottom.

 

[* velcro-fly *]

Nice, thanks for taking the time to write this up

 

[70 Mach 1]

sounds like a nice project for the right person.
when it comes to me and any type of saw or drilling the game is over
I fuck it all up every time

id rather spend the $45 for a new one lol