RE: How to make studs???
Swathdiver:
To get a bond as strong as molded in, you want to use a solvent glue. Some forms of thinner/varsol/turpentine work, but test them on a scrap first. The best is a solvent like Tenax-R or a similar no-name brand like MBS makes (APSC-1). The active ingrediente is Methylene Chloride.
The reason they work is they dissolve the plastic, and then as the solvent evaporates, the styrene re-hardens. Think like softening rice with water and then letting it dry again. As for placing the studs, mount them to the board, then place the board in place, and apply the solvent. A little pressure and the end of the 'studs' shouls squish out a bit, and then let it sit.
As for applicators... a Touch'n'Flow is best, but a fine brass or glass tube (i.e. a pipette) can be used, but for most solvents, an eye-dropper will leak all over before ya get it to your application point (I've tried it) In a pinch, you can use a brush, but make sure its a natural one (wood/metal/hair) as the solvent will slag a plastic one.
Yes, I speak from experience in using it... since trying it, I rarely use tube-glue any more, except as a gap-filler.