Custom Pickup Covers

[Chris Turner]

So, I don't know if I'll ever get to the point where I'll need custom plastic pickup covers made, but...

Where do pickup makers get their custom covers from? I'm not even sure where I would start looking.

Anybody?

[Marko Ursin]

I've made custom covers with silicone molds and casting urethane. For a one-off quite a lot of work but for even a few pickups makes sense. Not cost-wise but if you need custom, you have to be ready to pay.
Marko

[jason lollar]

Its typically done with plastic injection moulding and its a lot cheaper than having a stamp made for a metal cover but its still a couple thousand dollars plus having a run made- assuming you can draw the part in CAD.
The other way you could make a smaller run would be vaccum moulding but you are more limited that way and the per piece cost is higher.

The silicon mould thing works once you learn how to do it but then you are encapsulating everything.
I make a lot by using a plastic top plate and side wrapping the pickup with a thinner plastic like the photo.
I have also made metal covers out of pieces then solder it all together, sand it out level, polish and plate but I am not practiced at that enough to do it quickly.

[David Schwab]

I have also made metal covers out of pieces then solder it all together, sand it out level, polish and plate but I am not practiced at that enough to do it quickly.

That's what they used to do on the Travis Bean guitars.

Those plastic covers look great!

[Chris Turner]

[ATTACH=CONFIG]21896[/ATTACH][ATTACH=CONFIG]21897[/ATTACH]Its typically done with plastic injection moulding and its a lot cheaper than having a stamp made for a metal cover but its still a couple thousand dollars plus having a run made- assuming you can draw the part in CAD.
The other way you could make a smaller run would be vaccum moulding but you are more limited that way and the per piece cost is higher.

The silicon mould thing works once you learn how to do it but then you are encapsulating everything.
I make a lot by using a plastic top plate and side wrapping the pickup with a thinner plastic like the photo.
I have also made metal covers out of pieces then solder it all together, sand it out level, polish and plate but I am not practiced at that enough to do it quickly.

Okay. I figured I'd be stuck with either vacuum forming or making molds if I want to do it on my own.

Although, I'm very optimistic about where 3D printing is going. The resolution on the hobby-type 3D printers is getting better every day. Take the latest Makerbot, for instance: Replicator 2. It's a bit pricey, of course, but a resolution of 100 microns is pretty dang good.

[David Schwab]

I had someone 3D print me a cover. The only issue was the particular machine didn't leave a very good surface finish.

I've done the mold thing, which works very well.

[Marko Ursin]

[ATTACH=CONFIG]21896[/ATTACH][ATTACH=CONFIG]21897[/ATTACH]The silicon mould thing works once you learn how to do it but then you are encapsulating everything.

You can also make just the cover with a bit thicker walls. That's how I made some wood-looking plastic covers. This needs both outer and inner silicone mold.
Marko