I've made many from the proper sheets of laminated plastic from Warmoth, Stewmac and others. Make them by hand, cutting the general outlines with a Dremel, router bit and routing platform. Fine shaping with files and blades. Screw holes and countersinking with a drill press.
Here are the ones I did for my G-series:
The switch hole I filled at a later date when I started using an S1 switch instead of a toggle:
Plug cutter on the press, filed down to slightly oversize and pressed into place with some CYA glue.
Finally, my "Strat":
I still want to make a carbon fibre one for the Strat too. That's waiting until I have the downtime to fit a Hexpander, refinish the body and do a few other odds and ends.
