I've finally finished the pickup covers and routing templates. I actually started back on dec 24th, but I had a blowout with a thin wall and a router, and put it down for a bit.
I started with a design that fit pretty tightly around the actual pickup shape (jazz with ears cut off). The shapes on the drawing are the result of assembling the shape from boxes in a drawing program at work.
I razor it out close to the outside line and the glue that down to a scrap of MDF to make my routing template.
From there I sand it back to the line and run the router bit around it to make it smooth.
I then took an offcut from the body and planed it to pickup cover thickness with a router sled.
Then I screwed down the cover template to a scrap of MDF and made some rails around it out of more scrap. I routed around the edge of the template to clean it up, flipped it over and rescrewed it, and routed it again. Nice and smooth.
Next, I razored out some paper templates and glued them down to the pickup cover stock so that I could cut out the pickup mounting slots.
And I cut them out, right through piece.
I did it right through, because the next step was gluing a sheet of 3mm solid cream plastic to the pickup stock. This will let just the cream plastic be above the tops of the pickups when they are finally assembled.
After that, I cut out the covers with the plastic tops, drilled out the mounting holes and screwed the rough-cut pickup cover onto my routing jig.
And routed them out, one by one. Nice and smooth...
And voila, I have a couple of matching pickup covers. Walnut with cream plastic tops...
Next up, pickup cover routing templates for the body, and then will come routing for the pickups, drilling tuner mounting holes and other assorted holes, then mockup assembly and starting finishing!
Luckily, both are in spots that will be removed, but annoying just the same. 
