I squeezed in a couple hours work yesterday designing the pickguard for the build in Inkscape, as I dont currently have access to a CAD program, and dont need one often enough to justify paying for one.
Which is sorta ironic, as I have 3-person CAD team that reports to me. But directors dont get to 'do.' They just get to wave the stick. I'm 10 years past my last 'Drawn by' title block on a plan set.
Inkscape is very impressive for freeware, and works natively in SVG files, which are vector-based, scale-accurate, and laser-ready. Has a decent autotrace for going from bitmaps to vectors, too.
As the body dimensions and curves from the kit body differ from a production TBird, I can't just copy or scale the guard from my lovely '18, or buy one. A production one is way too long, and doesn't fit to the horn properly. None provided with the original kit, or even a drawing or template. On my own for this.
I made a serious effort to work up a design with old-school drafting methods; paper, pencil, french curves, triangles, etc. Too slow; those skills are 40 years stale for me.
So the process was:
*Finalize body shape and sand out 100%
*Trace down-side wing top surface outline by hand onto tracing paper
*Scan the trace as a bitmap 1:1 with my 4-in-one printer's flatbed, which was barely large enough for just the needed section of the body, horn to bottom pickup screw.
*Import bitmap to Inkscape, trace to beziers and clean up so I had a good model of the down wing.
*Print model and check against body. *Correct.
*Draw guard design in beziers by looking at my '18 and at pix of other production 'Birds, which showed that there's actually been a lot of variation in fit and detail over the years. Margins from body edge especially seem to differ, particularly near the neck.
*Copy an inset line to define where screws will go.
*Print on legal-size paper
*Cut out carefully and try against body.
Not looking too shabby in comparison.
View attachment 7374448
View attachment 7374449
I wanted a touch wider wood margin for visual contrast, based on tentative paint plans. Unlike Gibson models, I don't have a pickup wire route to hide, but I'm dedicated to 'capturing the spirit.' Espiritu sanctii.
Next will be decision tree time:
Should I print to adhesive paper and cut the guard by jigsaw, and bevel by hand, as normally I would,
Or
Should I use laser cutter/engraver to either cut it, or score it for saw cutting?
Bevel will be by hand either way, as my hobbyist-grade 10w laser can only cut at 90 degrees to surface, and it might not be up to cutting full-thickness guard material in a single pass. havent tried it yet. Bought it 8 months ago, have had time only to build it and test it. Still need to run the cutting calibration against actual sample material.
I've messed with router beveling guards before but I get a better result with hand files and a scraper. Lot slower, of course, but no need for a template guide, which feels kind of wasteful when only making one.
Also working up my personalized 'bird' logo and rod cover signature.
Might go with adhesive foil, might try engraving and filling. Will probably test both.
Also toying with laser-engraving a serial number on back of the headstock, pre-paint. Or I may make a custom water-slide instead for under the clear.
Need to test my planned finish, too.
So many decisions. So little free time.