How To Build David Gilmour Strat


The custom made routing jig/guide (clear Acrylic) used for precise routing of the small elongated hole in pickguard for the recessed mini toggle switch.  Using the rotary tool with the routing base attached the clear routing jig did not allow any lateral movement of the rotary tool, it only allowed for forward and backward movement required to create the slot.  The pickguard is held securely in place sandwiched in-between two pieces 3/16″ thick 7″ x 10″ acrylic sheets (free remnants at a local Tap Plastics) held tightly in place with four 6-32 mounting bolts which align with two of the perimeter pickguard mounting screw holes and two of the pickup mounting holes.  In both of the clear acrylic sheets there is a 3/4″ hole in the location where the slot is to be routed to allow access of the routing bit on the top side and clearance on bottom side.  The actual jig itself is made out of 1/2″ square acrylic bar stock and held in place on the top sheet of acrylic with “Acrylic Cement” which is a solvent type bonding agent that has the consistency of water and is a applied with a hypo-type applicator.  The bond that the acrylic cement produces becomes as strong as the acrylic itself for it literally fuses/melts the two pieces together.

This jig precisely aligned the rotary tool/router in the correct position and orientation for routing of the small elongated hole so when the mini toggle switch is mounted in the stainless steel recessed mounting bracket it would position the switch lever so it would protrude precisely centered through this small elongated hole.  It worked out great, when the toggle switch is flipped in either the up or down (on) position the toggle lever has approximately 0.030″ of clearance between all edges of the slot… Perfect!

Normally when the toggle switch is in the up position, towards the pickups it is in the OFF position, when it is down (ON) it selects or activates the neck pickup.  But of course this orientation of the switch can be which ever way is most comfortable and desirable for you and your particular playing style.

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