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I photocopy the plug on card stock paper (avery) and cut the profile carefully with scissors... then I tape this cutout with 3M blue painters tape onto the lexan and cut it out on my band saw... then I saw the profile with 120 grit in a rubber sanding block ... I turn a test plug and take measurements on the plug... usually I need to sand down a few spots on my lexan template .... best to creep up on the final profile to get what you want
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