Hi Olv, and welcome to the forums!!!
This is the thread where g.l.amour and I made our first #Rotor blocks, with a generous help of all the ppl here on the forums, here's the link, hope you'll find some answers on your questions:
http://forums.procooling.com/vbb/sho...p+setup+serial
as for CAD, if you're more familiar with Corel (my templates are all made in corel) will do the trick also...
You don't really need to spend too much money on bench drill, and for the tappers, just don't go and buy a whole set of diff dia, buy three pcs set for a desired dia, and don't skimp on this, buy decent ones (middle priced, or such). AND just don't forget to buy WD40 or similar, it helps a LOT when cutting threads.
Dunno for araldite, but you'll see that it's your choice in - bathroom silicone, goop, that glue g.l.amour uses etc....
Hope this helps, just go and do it, the fun is more than great!!!