My Easier (I think) Cathar Clone
 

http://www.helmetofshame.com/vanderlip/cathdesign.jpg

EDIT:: Copy and paste the source to see it, you have to download it, I don't know why! ::EDIT

The middle section is plexi and it has the nozzle drilled into the plexi using a drill press or hand drill.

the bottom part is 5-6mm thick and the channels cutt with a hacksaw to be as close to 1mm as possible.

the yellow parts are an epoxy sealing the channels on the end.

the blue area are places where the plexi top meets the copper, the red areas being where the plexi isn't touching.

the grey area is my o-ring using pond rubber cut out in the shape I want and then I am going to tighten it down with the inner 4 holes.

Please post your critiques in my method because I am just trying to make Cathar's design more DIY.

Cant view it no matter what I do.
How about posting the link.....It would be nice to see it:D

Not so sure how that epoxy is going to hold up.

If youre going to use it, your best bet would be to use marine epoxy.

When I first started making blocks, I used the drill press to do the cutting with a tungsten carbide Dremel bit from WALLy world.....

I put the copper in the cheap vise that came with it, and raised the adjustable base plate on the drill press to the approx. height I needed and turned it on low...... used my hands to move the vise with the block in it to cut out the channels to the desired shape.Using the tungten carbide bit, because of its large amount of teeth, I was able to cut the block slow enough that I didnt mess up the channels.

Worked pretty well....took a long time, and killed my wrists(hurt for about a week) but it done the job.And I was watercooled!

I then later upgraded to a mini mill since I was hooked on making blocks, figured I might as well do it right(or easier).
Which lead me to converting it to CNC and ultimately buying a bigger mill to convert also.

If you have the $400-500 , save yourself some time and wasted copper ect., and get a mini mill. Homier.com has em' for $399 I believe@ around $50 shipping, and that leaves you a few bucks for some end mills and a few end mills holders to put em' in....A slitting saw and holder would sure make cutting those small channels a hell of alot easier and you wouldnt have to epoxt anything.

Either way, good luck and let us know how it comes out.

Just a couple of ideias.

I've read in the forums (this and others) that alot of people eventually have cracks in the plexi/lexan. Maybe replacing it by a full copper top? You'd just have to drill the holes.

Another thing you could do is , instead of epoxy, you could solder it. If done properly it would hold better.