Decided to make a project of my $50 Peavey. Its getting a new candy metalflake paint job amd pickguard.  The body is smaller than a normal strat, so I'll have to cut the pickguard down to fit it.  If anyone has any tips or pitfalls to avoid, lets hear 'em

Do you have a scroll saw?

Yes sir. I figured that would the easiest way to make the big cuts.

The other thing you'll need is a router with a bevel bit with a bearing in it. Honestly, a pattern bit is the easiest way to do this job. Or, you COULD do the tracing thing and have a pickguard made. Last time I checked, it was $90 for WD Music to make one. There's a place out of Canada that will do it for $40 or so. I'll see if I can find it.

EDIT: It's called Greasy Groove. Their website is having issues last I checked but I emailed them and they can do stuff.

Ideally, start by making a template out of MDF. Bandsaw (or scroll saw, I guess) to rough shape, then belt and oscillating sanders to final shape. For the pickguard, bandsaw again for the major material removal. Then attach it to the template and use a pair of bearing bits - first a straight template bit, followed by a bevel bit.

It does make a mess - routers already make a big mess, and it's even worse with plastic pickguard material, which tends to static-cling to everything after it's blown everywhere.

Thanks guys. The template/router makes sense.  I've got the router, just need the bevel bit. I'll post up pics once I get started on the project

Made the template and modified the pickguard today.  I think it came out pretty well.  Not perfect, but you'd have to look pretty close to notice.

Before pics:




Template:



Finished:


ETA - I need to clean up the edge near the cutaway a little more after looking at the pics