zzpete,
OK briefly:
I use two compute programs. First CorelDraw to make the vector drawings. It has layers and lots of fonts and gives a sharp, crisp lines and numbers and had lots of colors. Since I've been doing this a while I have a few that I just use as templates and change for the next set minimizing the amount of work. See example below. So I've made K0, various K1s, K2, K5 and K6 plus some cafe type with some flags and crap.
Next I export the CorelDraw drawing as a jpg file and import it into Photo Paint. Then I size it for a 4X6 print and upload it to Costco photo finishing and usually order a dozen satin prints at 17 cents ea and have them delivered. The nice thing about Costco prints is they don't fade like what you might print on your inkjet printer
When I get the prints, I cover them with a layer of clear satin film to give them the matt look and protect the photo during assembly.
Then I cut them out and glue them onto to a plate using 5 minute epoxy really thin and weight it down.
Then the fun part with a really sharp XActo, I cut out all the slots and holes. I used to print the location of the slots and holes on the prints but that turned out to be a waste of time.
Since the photo I printed is on white photo paper, the white will show through the cuts and holes and will have to be touched up with a marker of the correct color when finished.
That's it. It's takes a few tries and throwaways but isn't bad once you've practiced a bit. I've seen peoples work where the holes look like crap and I've seen them where they look good. That's where the patience comes into play and having a dozen or so prints you can throw away if you mess up.
Putting the face into the gauge is covered here in multiple places including this thread.
Is that enough of a process?
I know some folks know printers and can get mylar film printed and I wish I could too but whenever I ask that person, I don't get a response.
