I've used a plexi pattern, which can be made by any means you like, to guide a really sharp knife. Double tape the pattern to the material for the guard. If you bevel the edge of the pattern it's easy to incline the knife and cut the edge of the guard with a bevel. A lot depends on the thickness of the material you're using, of course; it's best if you can make the cut in one pass, but that might be hard to do with heavy stock.
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