I'm taking a step back from the CBBG after a double sided tape failure so on my bench now is a replacement pickgaurd for my main bass, I'm excited to try this new materiel, it's a recycled plastic core sandwiched between to sheets of metal so I don't have to worry about shielding, I'm going to do a vinyl wrap over it when I'm done.View attachment 751190
EDIT: Trying to create a template from the original with the router completely failed and I'm not sure why, I was using a top bearing template bit and 3/8" mdf taped it upside down, trimmed of the excess with a jig saw, set the router depth so the bearing was riding only on the pickgaurd and when I went to route it made it a couple inches just fine then it would go into the pickgaurd, checked to see if it moved nothing, repeat a couple times and now the original has a bunch of little nicks in it. So I took it inside, traced it onto the sheet, used a jig saw to get close to the line and now I'm finishing it with files, and a drum sander. Here's where I'm at now.
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It sounds like you bearing was slipping in between the pick guard you were using for the template. I have had this happen to me before. This is why I need a router table. I think it would help a lot for things like this.




