Step 1: Tools and Materials
- CAD program (I use Sketchup because I'm cheap...)
- utility knife
- cutting board
- metal straight-edge
- Scratch awl
- drill and bits
- a few pages of cardstock, sized to work with your printer
Step 2: Make a 2D Projection
I made a 2D projection of the face of the white bar. On that projection, I carried forward the center of every hole that needs to be drilled (see the dotted lines) and marked the center with a cross-hairs. Additionally, I drew a circle around each crosshairs with the needed hole diameter and used Sketchup's dimensioning feature to note the radius for drilling.
Step 3: Print the Projection
Step 4: Cut Out the Template
Once you've cut it out, lightly score and fold the tabs, creating positioning guides as shown in the third picture.
Place the template on the stock and tape it into place as shown in the last picture.
Step 5: Drill, Baby, Drill!
Optional -- if you're drilling white plastic like I was, run some Sharpie lightly over the dimples. The hole will stand out better (see the second and third pictures).
Now, drill! I am making two identical parts, so I stacked two pieces of stock in my drilling vice (fourth picture) and then drilled my holes using the appropriate bits (twist bits for the smaller holes and Forstner bits for the big holes). The resulting parts (and a third part that shares a single hole with the first two) are shown in the last picture.