I just thought of something. What about body filler, its sorta like plastic/glue, you mix hardner then it sets to the shape you left it in. You could build a mould out of steel that has hyperdermic needles going through it (they were the right size wernt they? only prob was they are steel?). Then you mix up the resin with hardner, fill the mould and put a lid on it to sqaush it into the right shape/into the corners. The advantage with this is, assuming the needles are tapered at the end, you could achive very small holes. Infact you dont need hyperdermic needles, just any thin pin as the plasitc will set around it. there wouldnt be any mehcaniclal stress on it when being made, so it should be strong enough. I havent tryed using this on any blocks yet but I was originally going to use it to make a lid for my block as I couldnt get polycarb here in the UK. I think I may try this myself *IF* I ever try a jet impingemnt block.
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