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Hi everyone - the end is near for my two ongoing guitar builds. I purchased a couple of pick guards from Martin in the fall when I was down there for their factory tour. On my two current builds, the pick guards don't fit properly around my custom rosettes I made. Can anyone offer up how to properly recut the pick guards to the proper radius so it will fit around my rosettes? Also, these are bevelled edge pick guards too. Any ideas on how I can put the soft bevel back on the edge after cutting it to the proper radius?

Thanks guys, I'm so close to being done!

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Rob Flindall
Flindall Guitars
http://www.flindallguitars.com
https://www.facebook.com/FlindallGuitars

Rob: I assume the rasius is close to matching your rosette. You can either aquire a form or make one to wrap a bit of abrasive paper on, adhesive on the back type. Anything with the right radius,or make a tapered plug from a peice of pine etc., try 3.5" one end,4.5" the other and 4" long. The bevels can be scraped with a single edge razor blade,a rub with 400 or 600 paper and a bit of a buff.
Tom

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A person who has never made a mistake has never made anything!!!

Thanks Tom - The radius that goes around the rosette is pretty close, but not quite correct. I wasn't sure if adhering it to a board and then using a Dremel with a circle cutting jig would work (too much heat?) or if sanding it to size would work better. If you think sanding it to size is the way to go, I'll certainly give that a go.

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Rob Flindall
Flindall Guitars
http://www.flindallguitars.com
https://www.facebook.com/FlindallGuitars

Rob:

For some reason I end up making a lot of pick guards. I'm not saying the Dremel idea won't work - never tried it - but my experience is that anything that would generate that much heat is a no-no around plastic. I mostly cut them from blanks, hand sand to exact shapes, scrape to bevel, then finish sand and buff as has been mentioned.

For some reason, clear pick guards are getting real popular (and I like them). I've probably made more of those in the last few months than anything else. You might consider that also.

Jay