Best way to cut pickguard material?

[singlehum]

What is the best way to cut (3-ply) pickguard material? I need to make a couple of custom cavity and truss rod covers. Any input appreciated...thanks.

[Andrew]

By hand:

Fret saw for rough shaping, followed by a blade to scrape to correct shape, then paper (200ish) to smooth the edges. You can then gently scrape again to get a clean edge.

Manufacturers use a press and die/tool to cut them in bulk.

[carfish7]

A spindle or belt-sander is an awesome tool for refining the curvy bits or very straight lines (belt). Rough it out with a saw then use abrasives to get the finished shape.

Fret saw? Awfully wide for any turns IMHO. Band saw or carefull scroll saw work might be better if you have some radiused portions to cover. Gonna go for a bevel on those?

[Bennyboy-UK]

I like scraping

[rj2858]

I'd use something sharp!

Beats the hell out of anything else. Plasma cutter is overkill.

Hope that helps.

[jaberwock]

A jewelers saw; invaluable for cutting out pickup holes too, will set you back about ten bucks with blades, needs a steady hand, and practice otherwise you'll snap a lot of blades.

[crunchee]

Get somebody who does this for a living to do it for you. It isn't the cheapest way, but it's probably the best.

[Steve Haynie]

Get somebody who does this for a living to do it for you. It isn't the cheapest way, but it's probably the best.

Mess up the material once or break a saw blade a couple of times and the DIY gets more expensive. crunchee is right about getting someone who cuts pickguards regularly to do it for you.