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So I think I have the wrong pickguard, I am wondering if I should just get another or slight modify the one I have to fit better. I think I can pull this off by making templates the fit the plates I have and using them as a guide to remove material with a router. I think there is enough tolerance in the cavities to deal with the slight realignment of the plates.

I'm sure some one has dealt with this before. Experiences and advice appreciated.

4 way switch plate, perfect
Upper switch plate, daylight between plate and the guard, not much
Lower switch plate , pretty big gap. The angle is way off
The guard is allparts made in Japan, the lower plate is an american fender plate, the upper is from Custom World Guitar Parts in netherlands.



and here's the current state, clear done, waiting for it to harden before sanding
dry fit

From my experience building a couple of Jags last year from parts the aftermarket plates often don't fit perfectly with the aftermarket pickguards.. I'd say that's pretty normal from what I experienced. I mostly use CustomworldGuitarparts (NL) and eyguitarparts (China). Depending on the body (routed for US or MIJ specs) you should use a US or MIJ spec pickguard - the bridge holes and I think the upper horn control plate don't line up otherwise. With the plates I don't think there are US and MIJ versions iirc

The easiest way to make them fit is just simply place them as closely as possible on the pickguard, slightly overlapping it and use a black marker (if the plastic is still on the pickguard) - just trace the side of the plate using it as a template. Then use a fine wood file or 180 grit sandpaper to approximate the drawn line by sanding off the excess pickguard material (90 degree angle). If you do that slowly you can make the plate fit the pickguard perfectly. The round shapes are a bit tricky but if you sand that slowly and use something round with sandpaper 180 grit wrapped around it it's not too hard.

Easy process - just go slow and after couple passes try the plate and how it fits, before you remove some more pickuard material..

Turns out perfectly with a bit of practice

Thanks NiCQ, that had come across my mind as well. Probably the most straight forward solution. As you said go slow and practice