This is a continuation from part 1.
Below: This is our completed pickup template from a previous step, ready for use.
Below: Same as above, showing the back side.
Below: The pickup template placed on top of pick guard template, lined up as best as possible.
Below: The same as above, but flipped over (remember, the pickup template has hardboard and the pick guard template has plastic.)
Below: Marking the overhang, for the reason there will be no need to apply double-stick tape to that area.
Below: Tape has been applied to the back of the template.
Below: Razor used to remove the double-stick tape from the area of the rout. Important note: The way to see the rout through the tape was to hold the template up to a work light so it could be easily seen where to cut, and more importantly where not to cut.
Below: Pickup template adhered to pick guard blank.
Below: Tapping with hammer to make sure template does not move at all.
Below: Drilling a starter hole using forstner bit.
Below: A closer look at the starter hole area.
Below: Pick guard with template attached and a starter hole completed.
Below: A close-up of the specialty 1/4″ bit that was previously mentioned in part 1.
Below: The bit is installed into the router table (look to the center and you can see the blue of the bit shown in the photo above this one.)
Below: Adjusting the bit height using the edge of the template pick guard stack; the bearing rides on the template only; the cutter head comes all the way up through the pick guard material.
Below: Pick guard placed down, and getting ready to start the machine.
Below: Material is cut away.
Important safety note: All the material is cut away within the pickup opening as opposed to cutting a perimeter and having the center drop away. This is done to specifically prevent material from literally flying up in the face of the operator.
Below: The finished rout.
Below: Full pickups are fitted.
Note: It is highly advised to use the full pickup for fitting here, as a cover alone would bow, making for an improper measurement. The full pickup will not bow, providing a more accurate test fit.
Where are the rest of the build steps?
You can view them all here.