Making single-ply pickguards - just use the router?

[uOpt]

I want to make a single-ply matte' black pickguard. I have a pickguard to use as a template. So far so good.

I wonder whether I can just use my router and the Stewmac template bits and go?

Do I ruin the bits by doing so? Do I fizzle out the plastic? Is this practical?

And what's a good source for blank material? Don't feel like paying $30 :)

[Shepherd]

You should make an mdf template of your pickguard and use that with the router. The pg itself is too thin to use as a template. You wont damage the bits doing this. http://www.mcmaster.com/#85315k111/=4dktvz. They also have bigger sizes.

[Mr. B]

You should have no problem routing pickguard material, I certainly haven't.

I would suggest you first make an MDF template from the original pickguard, so you can concentrate on not damaging it. As the pickguard is bevelled, only a small section will contact the bearing so you'll have to take care that the router bit is positiond correctly and doesn't move up or down whilst you're working.

The method I would use is this:

- rough cut the MDF to shape

-Attach the pickguard upside down to the top of the MDF and have at it with the router.

Why upside down? Well hopefully the attached picture will explain it. It's not to scale, but the router bit will have a small gap between the bearing and the cutter. If the pickguard was the right way up on the MDF, you'd have to position the bit extremely accurately so the very bottom of the bearing was in contact with the pickguard and not the MDF underneath. In my view that's making things needlessly complicated. It would also leave a small section of MDF not cut.

Hopefully that makes some sense.

[littlericky]

What you can do is rough cut a piece of 1/8 inch masonite a little smaller than the pickguard and sandwhich it between the pg and the mdf. This extra clearance helps to make up for the gap between the bearing and "blades on the bit. It allows the bearing to ride solidly on the beveled edge of the pickguard.

[uOpt]

Sounds great. The pickguard I want to make is single-ply no beveling, so it's even easier.

Thanks, guys.