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Anybody have a good method for cutting out a cavity cover out of some .090" pickguard material. I've already ruined half a sheet.

I make a template of 1/2" MDF then doublestick the plastic to it. Rough cut to shape oversize with the bandsaw then trim with a piloted flush cut bit in the router.

Al

Thanks, we'll give that a try. Got half a sheet left to figure something out. I usually make them out of wood with not much problem, but that wouldn't look right on this guitar and plastic is proving to be an all together different critter to deal with.

I trace the inside of my router template that I use for the body cutout, cut a little oversize then trim with a belt sander for a perfect fit. That way all the fitting is done on the MDF, and not the P.G. material.

Al