Have you considered getting a Cricut? Sold at Big W.
Go to 17:30 in this build video fro a demo.
Have you contacted Ernest Peddinghaus to see if he could draw up what you want?
That's a clever idea. It just so happens that my wife has one of those so I might have a play around with it.
No, that could be an option but I'm just seeing what's out there at the moment.