So I have a couple of Fender PJ Mustang basses. Aftermarket pickguards for these are scarce and expensive! I was looking for a tortoiseshell example, but these seem to be especially expensive. I wanted my white Mustang to look a bit more vintage to suit the aesthetics of my band, and to make me feel less bad about the MIJ Mustang I sold on a while back. That bass looked cool, but the tone was too delicate for me. My white PJ Mustang runs on a set of Dimarzio pickups which are more what I want to hear!
I've made a few pickguards before now, but I've finally got it down to something approaching a standard process. The obvious solution is to make an MDF template and use a router with a nice sharp 45-degree bit. Get the whole thing carved out in the time it takes you to read this sentence!
I have none of the above, so I have to use hand tools.
I cut out the basic shape using a coping saw. I dial in the shape closer using a rasp, flat, rounded and circular files, and sand paper.
The trick is to sneak up on the lines, which I draw on the pickguard material (silver Sharpie for dark pickguards, black Sharpie on white material). I've seen a lot of DIY pickguards online that simply look rushed and ugly, probably because the builder was in a hurry to get the thing done.
The cutaway outline is the same diameter as a jar of instant coffee (I trialed a lot of jars and tins in the kitchen), so I stuck 180 grit sandpaper on this and had at it!
The only truly problematic area is around the control plate. However I have two WD Music pickguards in my possession that are no better at this area:
I hand-turned each countersink for the screws. I've found that you can't do this cleanly enough with a hand drill.
The 45-degree bevel is carved on last. I colour the outside of the pickguard with black sharpie and then carve the bevel with a Stanley blade. I carve until the white of the lower layer appears from under the Sharpie. I also keep an eye on the black line in the pickguard material as this has to look even.
