Official Luthiers Forum!

I've got a control cavity that needs a new cover, and its an unusual shape. I don't have an old cover to make a template from. Any tips on the simplest way to transfer the shape to the pickguard material? I've tried putting paper on top of the cavity and using a pencil to shade the outline, but it seems to keep coming out over sized.

Can you put masking tape over the cavity in overlapping strips then cut along the outline with an exacto? That would give you a positive and negative (the tape left on the guitar) template. These would not be absolutely perfect but you could use them to get really close. Then you could use that to make a template to carefully trim to get a nearly perfect fit.

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Bryan Bear PMoMC

Take care of your feet, and your feet will take care of you.

Put tiny brads in the screw holes - make sure they stick out slightly farther than level with the back and have sharp points. Tape a piece of paper over the cavity, push down on the brads to puncture at the screw holes. Cut along the edge with a sharp Xacto knife. Stick the inside cutout to your plastic with double sticky tape. Cut it out on a band saw, sand until it fits perfectly, drill and counter sink the holes. If you have sticky tape left on the plastic clean it off with naphtha.

I use the paper method and then make it a little smaller because you are tracing the outer edge of the hole.

I also use a thinner black ABS and score it with a razor and it just snaps right off at the line.

I make a lot of covers and a lot more back covers for strats.

I usually just give them to the customer because they are so quick and easy to make. Oh, and a belt or disk sander comes in handy for fine tuning.


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