Does it matter what size I would use for a guitar pickguard with a thickness of .120? This would be my first time using a router.

My older brother is a master guitar builder, I am not. That said, use the smallest bit that will completely cut the material in one pass. The top bearing should ride on the pattern and for safety, leave the least amount of cutter exposed. This is best used by having the router mounted in a router table and the pattern on the bottom of the material to be routed. If you don't have a router table, then you will need a 'spoil board' under the material and the pattern above. Use double-sided tape to attach the pick-guard material to the pattern and (if used), the spoil-board. The other choice is to use a 'flush trim' bit with a bottom bearing. The pattern will need to be thick enough to account for the bearing and the screw that holds the bearing. Either way, it is best to 'rough cut' the pick-guard material so that the router only has to cut the least amount of material. That should give you the best results.

Maybe a silly question, but how to get them out of the plastic case they come in? It's like they're glued in!

Remove the outermost plastic film with your fingernail from the top, or use a small knife you can control without cutting yourself, then pull off the blue cardboard cover from the now outside. Pull the little black fold up handle on top. Use care not to break it if you want to keep them within the handy box. They can require that you pry them out the first time.

Does the ka001 bearing kit fit the kowood pattern bit set? https://www.amazon.com/kowood-pieces-bearing-replacement-ka-001/dp/b096xgv9rr

Not sure Scott. I would have to measure the bearings on the existing set. I will look to determine the dimensions and repost to this response. Mat take a few days to do so though.

Are the bearings interchangeable? I'm wanting to use these similar to a rabbeting bit.

The Kowood kit that I bought contains PATTERN top bearing flush trim bits (Style: “Pattern Flush Trim”, $16.47). This appears different than the photo link that is with your question (Style: Straight Flush Trim). The description in Amazon from Kowood is almost identical for the two types which can be misleading. The PATTERN top bearing kit has the bearing on the shank closest to the router collet. The Straight flush trim has the bearings on the far end of the bit. Also, when you ask about the bearings being interchangeable, do you mean within the same Kowood set? Otherwise, the Kowood bearings may not fit other bits depending on the manufacturer. For example, I cannot use the Kowood bearing on a CMT bit that I have, but could go on anything with a ¼” shank. The kit comes with a small hex wrench to remove the bushing below the bearing. These are removable. However with the top bearing PATTERN bits that I have, you wouldn't need to remove the bearing to make a rabbet cut. You would simply plunge down and make the cut. I am using mine to run inside a home-made dado jig. The Straight flush trim bit kit cannot be used to do a rabbet because the portion below the cutting edge would not allow the cutters to get to the bottom of the rabbet. Either buy a rabbeting bit for that purpose or buy the Kowood PATTERN flush trim bit if you want the option to do rabbets.

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