The Routing:


Look at my routes for the pickups:



Here, the pickups are just laying in the openings.  I wanted to show how the pickup fits into the end area of the existing humbucker route very nicely.  When you order a custom cut pickguard, the measurements are 2-5/8 inches from the heel of the neck to the bridge side of the neck pickup.  And 6 inches exactly, from the heel of the neck to the bridge side of the bridge pickup.  If you use those dimensions, you'll have an easy go of the routing.  You can use the normal bridge pickup mounting location if you want to.  I decided to go for the easier routing.
 


The above shows the pickguard in place, and where I used a bit of black marker to trace out the area that needed to be cut away.  Marker worked ok for the photo, but I went back and retraced it with a sharp black pencil.

Below, you can see the area's removed in green, and the places to make the pickup openings.  The sizes shown are NOT the route sizes, they're the PICKGUARD opening placements! 
I just traced the pickguard openings from the pickguard, when it was mounted on the guitar, then cut a little bigger.  You can see my "score" marks.  I did that because the router was really kicking up some dust and I just could not see too well.  The light scoring helped a lot in that respect.



Take a look at the green areas in the picture above.  See how the back of the original neck pickup cutout had about 1/4 inch taken from it, and the side sections had about the same taken away?  See how the bridge pickup really only had that one side area enlarged, and then just a little nub removed at the wire opening?  Another way routing is to use the standard pickup location for the bridge pickup.  There is no right and wrong here, they're just different.  Just make sure you use the pickguard you get as a template for making the route cuts.  Be sure to screw the pickguard down, then mark the areas to be cut with a sharp pencil, then only cut those areas! 

Thinking about it, I suppose moving the bridge pickup back just a little also helps the bridge pickup get just a bit more bite.  I wondered why the original SG Specials and
SG Classic had the bridge pickup set so far forward.  I thought maybe it was to help with balancing the volume, something I see now is not the case, as mine balanced quite nicely.

I used the Dremel router base attachment with the 1/4 inch router bit, which was excellent and a woodhog.



It ate up the mahogany like nothing!  Go slow.  Do a good job.  The router can hurt you bad.  Be careful.  WEAR EYE AND EAR PROTECTION.  Keep in mind the router can kick back.. so you always cut against the blades rotation, not with it.  Practice on some scrap wood to get the feel for it before digging into your SG!

WARNING: Please be sure to read all the directions and safety notices in the Dremel manual (or the manual for whatever tool your using).  Don't only read them, follow them!  You only get two eyes, two ears and ten fingers.  You need them all.  So be careful!

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