I'm working on a waterblock design with the intention of it being relatively easy to make (I.E. not requiring any milling), but still having competitive performance.
The design is sort of a crossbreed of the RBX and WhiteWater designs because this staggered drilling pattern offers the best fin density and turbulent surface.
The base is 3"x2"x.188" with .125" (3mm) channel depth.
The top is a sandwhich of two .188" thickness polycarbonate or polyester (PETG) plastic sheets. This will make the top extremely easy to machine because they can be cut out to square dimensions on a tablesaw, drilled, and then tapped before being solvent-glued together.
After finding sheets of plastic in the right thickness I realized that I can make an o-ring groove without having to mill it out of either piece. The outer lip of the top is then glued on and the inner lip bolts into place from underneath using countersunk screws. This will allow for different nozzle designs to be added by simply swapping out that piece. Or alternatively it could be glued in place instead.
Thoughts? Once I've made enough revisions and made a prototype I will make a complete set of cutting templates that you can print out on label paper as well as some instructions.