We buy the vintage brown and fire stripe material from Axiom, make up a template from 1/2" MDF, rout with a flush cutter, bevel and blend the edges with scraper, sand and buff, then mount with 3M 467M (available on Ebay at reasonable price in a variety of sizes) using the wet technique. For darker material, check Holter Guards...he seems to have a lovely pattern which matches the darker Martin guards.
https://www.facebook.com/holterpickguards/
We have used both the Tortoloid material from Mario Proulx (available through StewMac) and the Tortis material (available from LMII) - very similar dyed/colored epoxy - we thin to .025"-.028" with wet/dry, as the stock material is closer to 0.035" and can look a bit bulky.
For patterns, we have a box of them collected over the years and marked with instrument and date...for the recent BRW/adi 12 fret 000-42 and the two D-42 12 fretters we completed, the patterns were roughed using the vintage 12 fret 28-style patterns for 000 and D, and tweaked using shots from the VintageMartin site's collection of photographs of 40-series instruments.
http://vintagemartin.com/pickguards.html
On peel and stick material...we've used both the 3M single ply (as sold by Stewmac) and the two ply with scrim...the 3M 467MP two ply material is much easier to use and is not noticeably thicker after application. The only downside is that the material must be accurately trimmed to avoid having any portion of the scrim visible after application. Trimming with a fresh, quality single-edge razor blade using the 'ride the bevel' technique gives a very close, accurate trim.
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