+ 1 on cavity adjustment with dremel + sanding drum.Originally Posted by McCreed
Another good tool for working on pickguards is just a Stanley knife blade held in the hand (without the "knife" part).
It can be used as a scraper and affords a lot of control if you looking to remove a little bit at a time. Actually, you'd be surprised how much material you remove quickly as well. They're good for both fine tuning bevels or heel and vibrato cut-outs.
FWIW, the plain old blade has a plethora of uses doing this kind of work.
[Edit to add: Fine sandpaper used dry then wet will clean up the new edges nicely. You can even use a bit of polishing compound after.]
Like Simon, I was going to suggest a sanding drum on the Dremel for widening the control cavity. Definitely less risk of accidental or incidental damage.
BTW, that first fret is #@#$^ mess! (but you probably knew that already)
Routers are wonderful labour saving tools but to be safe and protect your workpiece, you have to know exactly what you want to do and jig/ template accordingly.
it is possible to freehand effectively, many here have done so, but I wouldn’t attempt it on your first ride.
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