Creating a Pickguard from scratch sounds like an easy process right?.....right.
First thing I did was create a plywood template from the original pickguard. From this template I cut the new pickguard from blank 3 ply stock. I then beveled the edges and cut the hole for the pickup. This was interesting because no one sells templates for the Gretsch HiLotron pickup...so I had to cut the hole by hand... Yes, I screwed up a couple of blanks before I got it right. Next was Pot placement. I made a rubbing of the cavity so I knew how much room I had for the pots. As soon as I had the layout and spacing I found the centerpoints and drilled. Almost done!