Here's the cutting template file.
http://www.captainslug.com/modding/krakatoa.doc (144kb)
And here's the materials list for making the waterblocks
Code:
8574K24 - Polycarbonate Sheet 1/16" Thick, 12" X 12", Clear = $3.51
8574K26 - Polycarbonate Sheet 1/8" Thick, 12" X 12", Clear = $5.50
8964K415 - Alloy 110 Copper Rectangle 3/16" Thick, 2" Width, 1' Length = $20.83
9407K11 - Buna-N O-Ring Cord Stock = $1.00 for 5 feet
To make the two O-Rings you simply need to cut two 7.5" lengths from the stock and glue the ends together using super glue. The pieces go together like so.
Use IPS Weld-On #3 or #4 to glue the 1/16th" thick pieces to each other (excluding the nozzle plate if you want to be able to remove it). And similarly glue the 1/8th" (or thicker) together. Add the O-rings and then bolt the unit together.
The design is meant to be adapted to what tools you have available.