Consider Formica for cavity covers and pick guards. 4x8 sheets are as expensive as hell, but search Home Depot for "Formica Samples". 5"X7" pieces for 25 cents each....

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Good idea, but right now I'm making nuts (and some bridges) out of aluminum, angle.

I am, however, all about the free samples...

I've tried the Corian for nuts, more pain than it's worth. I use bolts for nuts and bridges, steel or brass and they come with grooves for holding the strings.

You can get grooved bone or Tusq nuts from Stewmac for 5 bucks plus shipping(use the Ukulele nuts for your CBG's. you can get a sheet of pickguard material big enough to make 2 Strat guards for about 12 bucks and cut them out yourself.

Got some today...

Unfortunately Corian isn't the only manufactured stone out there. You can cut corian with a standard saw. Caesarstone will blunt your saw faster than anything else I know, and I know from personal experience.

Not Formica, but I have used hardware store Galvanized sheet for covers? You can also get thin copper & brass sheet from craft stores?, another option? 

I just found some small pieces of very thin brass that I'm gonna use to ground the bridges on my stuff...

Keep in mind that metal pickguards have an effect on how your pickup will sound.

Steel can either help or harm, brass can block treble, copper is usually good and aluminum can block 60 cycle hum in single coils if it's thick enough.

Thanks for that info. I'm learning stuff here all the time. The brass I used is postage stamp size. Soldered tonight, still a very minor hum, but much much better.

Wasn’t gitty selling those vinyl pickguards at one time? I remember Shane did a video about one many moons ago, still kool tho!

Tried , tested, and true  ;-)

Thin plywood and now trying masonite. A bit thicker than normal pick guards at between 1/8 to 3/16. But easy to come by. 

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