1. Part Design:
   You need to locate a vector drawing program capable of printing your design to scale, I have found that PCB layout software seems to function very well in this regard. Once you have familiarized your self with the selected software package, you can begin to develop parts. There are 2 basic types of parts you will need to make, flat parts, and parts used for connecting every thing together.

   Here is an example of a flat piece:
   

   Here is an example of a connecting piece:
   
   I usually use 90 degree angle stock for my connecting pieces, when putting your template on to angle stock, you want to put it on the inside, this makes it much easer to cut, as well as figure out the measurements during design time.
   
   Once you have designed your pieces you should be able to print them out on a full sheet label (Avery 8165). Use a pair of scissors to cut around the part, you want to keep your label as close to the size of your part as possible, this will help conserve material. Now you're ready to stick your label to your material, I prefer aluminum, however, there are many types of building materials available including wood and plastics.

2. Fabrication:
   At this point you should have your material and a template to work with. I usually start by drilling all of the holes; smaller parts can be a pain to drill if you cut them first, when there isn't enough room to hold the part properly. It's a good idea to use a center punch to get the holes started in the proper location. Now you can cut your part, I like to use my band saw for larger pieces and my scroll saw for smaller or more detailed work.

   
   Here is an example of some finished parts using this technique:
   

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