Thanks guys - bogstandard, yep, I agree lifes to short...I don't need a whole lot of accuracy, but never having made such a beast was just curious as to how they did it! 2e0poz ....a couple of nice tips there - I especially like the first one :-)

Robin...I'm having diffs visualizing what you're suggesting. Going this route, then cutting from stock would obviously be quicker per piece ...but wouldn't the pieces still need deburring? (it's this aspect that's the real pain in the backside)