A pickguard serves as a protective barrier, typically on guitars, shielding the instrument’s finish from scratches caused by picks or fingernails during playing. Customizing this component allows musicians and hobbyists to personalize their instruments, often requiring a shape that is not commercially available. Cutting a custom pickguard is necessary when using unique materials, such as specific acrylics or pearloid sheets, or when replacing a non-standard shape. The process involves careful preparation and precise shaping to ensure the new piece fits the instrument’s contours perfectly.
Essential Preparation and Tool Setup
The process begins with selecting the appropriate sheet material, often including PVC, acrylic, or celluloid. Thickness is an important consideration, typically measuring between 1.5 and 3.0 millimeters, which influences the choice of cutting tool and technique. Precision starts with the template, which should be traced directly from the guitar’s body or an existing pickguard using a fine-tipped marker to ensure the correct fit and accuracy.
Once the template is transferred, the sheet material must be secured firmly to a stable workbench to prevent movement during cutting. Using non-slip matting beneath the material and C-clamps ensures both safety and a cleaner, more controlled cut. The primary tools for shaping involve a high-speed rotary tool, such as a Dremel, or a manual coping saw, depending on the material’s density and thickness.
The rotary tool should be equipped with a specialized plastic or spiral cutting bit designed to minimize friction and heat buildup. For thicker materials or very intricate curves, a coping saw or jeweler’s saw provides a slower, more controlled action. Having various grits of sandpaper and a small file nearby is also helpful for initial edge refinement immediately after the bulk cutting.
Step-by-Step Cutting Methods
After the material is secured, the first step is to remove the bulk of the material, staying approximately three millimeters outside the drawn template line. This rough cut is best achieved with a coping saw, using long, steady strokes to prevent splintering or excessive friction. Straight lines can be guided by a clamped straightedge, but the final, precise shaping requires a more controlled tool.
The rotary tool is best suited for precise contouring and navigating tight curves and corners. When working with plastic materials like acrylic or PVC, the tool speed must be carefully managed to prevent the material from melting and re-fusing behind the cutting bit. A lower speed setting, typically between 10,000 and 15,000 RPM, is recommended to reduce the heat generated at the point of contact.
If the material begins to soften or gum up, it indicates the rotary speed is too high, or the feed rate is too slow, causing thermal deformation. To counteract heat, the cut should be performed in short, progressive passes rather than trying to complete the entire depth in one continuous motion. Using a specialized spiral cutter bit helps evacuate plastic shavings efficiently, further minimizing the thermal load on the material.
The goal of the cutting phase is to approach the template line closely without crossing it, leaving a small amount of material for the subsequent sanding and refining steps. For complex curves, the saw or rotary tool should be kept perpendicular to the material’s surface to ensure a clean, vertical edge.
Sanding and Polishing the Final Shape
Once the bulk material is removed, the edges require refinement to meet the template line exactly and eliminate rough saw marks. This process begins with coarse sandpaper, typically 100-grit, to quickly file down the remaining material to the final shape. Sanding should be done using a rigid sanding block to ensure the edge remains flat and perpendicular to the face of the pickguard.
The sandpaper grit must be progressively increased to remove the microscopic scratches left by the previous, coarser stage. Systematically move from 100-grit to 220-grit, then to 400-grit, and finally to 600-grit sandpaper to achieve a smooth, matte finish. If a bevel is desired, the edge of the pickguard is sanded at a slight angle, typically 45 degrees, which is a common feature on many guitar styles.
The final step is restoring the luster and shine to the edges using a polishing compound. Apply a plastic-specific polishing compound to a soft buffing wheel or cotton cloth and run it along the edges. This mechanical action, combined with the mild abrasive of the compound, brings the edge to a high-gloss finish, completing the custom shape.