New Guitar Project

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Depth & cover ledge look great Ray!
I'd straighten the edges like Don says, and just make a slightly oversize cover to fit the opening.
It'll be perfect.
You've got a nice belt / disc sander, Find an old pickguard in your stash, cut a piece to rough size & have at it.
 
Ray, we will get you fixed up and you will learn a valuable lesson. How to do our best to avoid this in the future but if it does happen, then how to fix it and make it so no one ever even sees a flaw.

I am inclined to agree with Dave at this point.
I believe it was DonO who suggested straight edges and run router in there to clean up the edges. From your pics, I think I might try it with striaght edge right up tight to each end of the circles and run a razor knife down the stright edge to clean up the wiggles.

Dave said to get another piece of cover and fab up your own precise fit one. I agree.

I decided to amend my advice after seeing Sg John's post to follow.
 
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Depth & cover ledge look great Ray!
I'd straighten the edges like Don says, and just make a slightly oversize cover to fit the opening.
It'll be perfect.
You've got a nice belt / disc sander, Find an old pickguard in your stash, cut a piece to rough size & have at it.
Thanks.

That is an idea. I actually have these sanding drums and a platform with a hole in it that I made for custom PGs. However, I fear my fab cover will not have straight lines either!!



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Good work, RVA - looks lovely.

You've taken a lot off. I was trying to compare it with my tele cut:

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View attachment 59861

You have beautiful looking wood, Sir, and quite the depth to the comfort cut.
Thanks! I had the luxury of holding it up to my body to see when it felt comfortable for my seated playing. I did not cut as much as others I have seen.
 
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