I'm not a big fan of the refrigerator-white color pickguards on Danelectro guitars. I wanted to put a pearloid pickguard on the DC-2, but it seems no one offers them commercially.
So I procured a hunk of pearloid material and set about making my own.
First step (surprise) was to make a tracking of the stock pickguard onto my selected piece of birch laminate.
Now, I will warn you, dear reader, of the mistake I made before you read much further.
A piece of plywood/laminate is not the best choice for this operation. A solid piece of hardwood, maybe even MDF, would be better.
We'll find out why shortly.
I cut away most of the excess around the pattern.
So far, so good. It's going well.
But we're close at this point. Just need some finessing.
STILL waiting for the endorsement deal.
Here you can see I traced the pattern onto the back of the pickguard material. Then I cut it on the bandsaw.
I screwed the pickguard down to the the template and then I did a pass with sandpaper to smooth the edge to align with the template.
Looks good at this point, and no acccidents.
Whiteside 45 degree router bit to make the bevel cut with.
This is a closeup of the bit in the router and being aligned with the template. The bearing on the bit will ride on the template while the router bit cuts the bevel on the pickguard.
But here's the catch I alluded to earlier. The edge of the template needs to be perfectly smooth - no bumps or divots. Since the bearing, and by extension, the bit itself, follows the edge of the template, any bumps will be cut into the material.
I was too
But next time, I won't use plywood for the template. A solid smooth surface is key to getting a perfect cut.
The black marks near the one hole are on the protective plastic covering the pickguard, so they will be gone when I peel the plastic off.
This was a good learning experience. Next one I do will be perfect!