Template or pattern routing would be a low cost and personally feasable method that lies between Nick's and John's suggestions.
Nick's suggestion on one hand:
Quote:
Back to the old fashioned way.
1. Make templates and trace out on your ply sheet
2. Cut out with a jigsaw
3. sand down to the line
4. cut out with hole saws & jigsaw
5. Make Tons of sawdust!
|
and John suggested contracting out a cnc router.
Your tool requirement would be a router table with router and a pattern bit, drill to start a hole in the lightening holes, and a jig saw to cut out your rough blanks.
Make the pattern out of thicker and durable material (hardwood, plastic,MDF, Masonite, etc.) using the old fashioned way, sand the edges smooth to the line and that is the only one that needs strict attention.
You could gang several layers under the pattern and mass produce in your own workshop. With a shop vac or dust-collector attached to the router table you can cut down on sawdust. A couble of vertical handles on the pattern and you have easy work. When you are done you will still have the pattern to hang on the wall and use again when needed.
observing,
Fee2b
Michael Scheetz