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Gene Simmons LoBue Tribute Build

I made a template to grind down my pickup.
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This is the part to be removed.
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I also painted the template black for grinding depth visual aid.
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I also began plotting out my trus rid access rout.
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I am knocking on the door of completing fabrication.

Pickguard template cut out of MDF.
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After final shaping of my template, I traced out the template on pickguard material.
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After rough cutting with a band saw, and taped to the MDF template.
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After routing out the pickguard and rounding off the edge.
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The plastic wrap came off during round over. I now have a few scratches on the pickguard, but I think I can buff them out.

After 40 minutes of some shaving, the pick guard fits decently. Not perfect, but life isn't either. :-)
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Pickguard in final place.
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I also shaved my pickup cover.
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I also tried to use a router bit for the trus rod access. Using my test piece, I soon found out that I Need a rat tail file and Dremel to get it right.
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Almost done with fabrication. Stay tuned!
 
That pickup cover cutter downer jig looks to have worked pretty well :D

The pick guard looks great, very professional looking.

Thanks! The jig worked awesome! The best part; if I need more off, I can just make a more shallow jig.

The only thing I struggle with now is accurately cutting the pickup hole out if the pickguard. I should've cut the pickguard before routing out the pickup cavity. Things you learn.
 
Thanks! The jig worked awesome! The best part; if I need more off, I can just make a more shallow jig.

The only thing I struggle with now is accurately cutting the pickup hole out if the pickguard. I should've cut the pickguard before routing out the pickup cavity. Things you learn.

do you have a top bearing flush trim bit? Drill a hole that the bit will fit in, and use it in your router to cut a matching hole that is in your body.
 
I drilled out the pickguard for an inspection hole.
From there, I used a small router bit to widen the hole for a bearing router bit.
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Using a pattern bit, I make a matching hole for my pickguard.
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Pickup cover now mounted. The only fabrication I have left is to shave out the trus rod access channel.
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The neck on Genes original was tilted back more and its heel did shift over the years very slightly, the neck rod adjusted flat but the action could no longer be lowered .
I would tilt the neck back a bit by shaving the heel and shim the bridge and bolt it till it all sets before gluing. You can then counter sink the screws AND glue, and cover it

Then the neck angle was too steep. You want some adjustment in either direction. A steep neck angle would only be needed for a tall bridge.

There's no need to screw and glue. I have made several set neck instruments with no tenons and they are doing fine 19 years later. Using screws would make it impossible to remove the neck should that become necessary.
 
I talked to a few smart folks. I'm going to make sure my neck heel is free of finish, and I will glue it without screws.

In related news, I think shaving the pickup gave me the proper clearance I need. I will post setup pics tonight.
 
I did some light work tonight.
First, I countersunk my pick guard screws.
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Then I installed screws in my control cavity.
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I also Dremel'd out my trus rod access
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I marked off the neck where I would sand the edges off the neck.
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I wonder how much I should grind off this lip on the body? Thoughts?