On the Indiana shaped pieces, I laid out the shape in Corel Draw. Printed full scale and made a master template. Using a pattern bit, I was able to cut out consistent shapes on my router table. After cutting out I used the 1/4 " round over bit to smooth the edges. For the 5 x 7 size pieces I sawed out on my table saw and used shaping bit for the edges.
This project was a bit of an undertaking, but for the cause it was worth every bit of it.
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