Hi Casey. I've managed to cut several pick-guards via differing techniques.
Best way was with a jig-saw and files and sandpaper believe it or not.
I'll lay the acrylic flat on the desk with minimal over-hang to reduce the vibrations.
Like everything else it does require some repeated attempts to nail it correctly.
Practicing on MDF is also a good method
cheers, Mark.
cheers, Mark.