Needed a slightly bigger control cavity cover so thought i'd share how i make a set of templates.
First i make a new cover plate in mdf, i will then copy this with a flush trimming bit which gives me a better Master Template with nice square sides.
I now need to make a routing template for the new cover.
So roughly hack out a hole in some mdf that is 4/5 mm bigger than the cover template,
I then add a few layers of sellotape to the cover plate template edges. This will help to make our routing template [i]slightly[/i] bigger than the cover plate. I don't want it too tight. Cover [u]this[/u] tape with silicone or vaseline to stop any resin sticking to it.
I have also sealed the bottom what will be the 'mold' with sellotape....
Flip this over and sit the Cover template inside. This now gives a seal around the whole assembly.
Nip to Halfords...get yourself some fibre glass resin (and hardener) £5.00 a pop for a small bottle.
Mix it and pour it in the gap between the mold and the cover plate template...
Note I have made a few little 'wells' in the mdf to help pour the resin, this also helps to key the resin to the mdf when it's set.
Nip out for a brew...it will be hardened by the time you get back.
Take the sellotape off the back and pop the Cover plate template out, remove the sellotape from the edges...
Et Voila ...... a new control cover plate template AND a routing template for it
PS
You can use the same technique to make pickup routing templates AND neck pocket templates.....
Hope this is some help to someone, i find it makes a far better job that trying to fit covers by hand !
IanM