cutting a blank pickguard

[dijos]

I'm putting a p90 and a tele bridge pickup in a project I'm doing, and since it needs a strat pickguard, I need to get a blank and cut the holes for the pups.

What do you use for the cutting? I have extensive woodworking experience, but I've never cut plastic. I figure a hole saw, jig saw, and files or a dremel will work, but does the plastic melt or bind?

also, any tips for making sure the tele bridge is at the correct angle?

[jwells393]

Pickguards are best made by rough cutting them, taping it a template then doing the final cutting on a router table. If you're not equipped to do that it can be done with hand tools. Use a fine tooth blade and a slow speed with the jigsaw.

I'm unclear what you mean by the last question.

[mellecaster]

I've heard from some Scrollsawers that they cover the plastic completely with the clear or brown plastic Packing tape...and the adhesive in the tape lubricates the blade to keep the plastic from melting....I've used a Jewelers Coping saw by hand w/ pretty good results...kinda slow, but if you're just doing a one off, it shouldn't be a problem.....And I don't feel the angle of the Bridge pup is that critical IMO...hope that helps.

[crowden]

A Dremel would work but you would probably need one of these to do it right.

If you need a cheap/small router to do light weight jobs like this, Harbor Freight has this one. There's a Harbor Freight in the shopping center at the corner of East Bay and Belcher (If that's St. Pete, FL your from). I got mine for $19.99 at a tool sale - which they have all the time.

Keep in mind that you still have to "ruff it out" and make a template to follow but, once you have a template, making future pickguards from it are a piece of cake. I use a cheap 1/4 inch shaft 45 degree bevel bit with a bearing on the bottom to make mine. Just use double sided tape to attach the material to the template and then make sure that you clamp the whole thing down good before you fire up the router.

Now, your not going to do a whole body from a blank with one of these but it is suitable for making pickguards, enlarging pup cavities, reshaping a headstock etc. as long as you go slow and let the tool do the work at it's own pace.

[reddogbass]

I use both a bandsaw, and a router for cutting pickguard material, depending of course on whether I want to make a template or not. For the pickup holes, you can use either a router or a scroll saw. The material really doesn't melt, but you can see evidence of heat, so move along quickly- it won't melt. You can sand the edges with a drum sander if you need to. Finish by hand.

[jwells393]

On recent pickguards, I've rough cut them with a scroll saw using a spiral-fine-tooth blande which cuts in any direction. I use a medium speed which prevents heat buildup.

As a heads-up, my local Lowes has the Hitachi scroll saw for sale at a reduced price of $149 with an included $20 or $25 gift card. I paid $159 for mine. Sounds like a deal to me and I give the saw a thumbs up.

[mellecaster]

Not meaning to Hi-jack the thread....but Jack...I've had one like this gathering dust in the corner of the Shop for years, and was just wondering if there is a large learning curve on using one...I've got a few good books on them, but would value your opinion, on how much skill & practice is involved ?...I reckon like most things, you would have to use fairly often, to get the Hang of it.

Attachment 11023

[jwells393]

I've only had mine since January. I'm definitely no expert on using scroll saws. I bought it when I got the idea for building my Acrylicaster. I think I was looking for an excuse for buying a new tool.

I bought a really cheap scroll saw at a garage sale once for $40. The saw worked but would not cut a fine line because of lateral movement of the blade. The saw was crap but it came with about $100 worth of spiral tooth blades.

I think Drak ...... member here .......actually cuts bodies out with a scroll saw.

[Colt W. Knight]

I haven't built any guitars, but I never found an application for my scroll saw except arts and crafts type stuff using really thin wood. Ive always preferred my band saw. As for cutting bodies with a scroll saw, Ive never been around a scroll saw that was tough enough for that. Im sure they are out there, but the ones I have are pretty much worthless.

[newey]

dijos-

also, any tips for making sure the tele bridge is at the correct angle?

I assume by "correct angle" you mean the same angle as on a Tele bridgeplate. I agree w/ Melle, shouldn't make a difference tonally so long as you're close. But if it's an issue of looking "spot-on", I would use a Tele bridgeplate as a template to mark your pickguard. You would need to square up the Tele plate to the Strat-style bridge cut-out in the pickguard, slide it forwards or back to get the location you want, then use the holes in the plate to mark the pickguard.(or mark the masking, might work better as noted above).