RE: Templates, how to make!!!
The sanding drum was just one I had that came with a kit of different sized drums. I added a bearing of the appropriate size. You can get these drums with a bearing from places like Woodcraft, as noted above. With a 1/4" shaft, they can be used in a drill press, or a variable speed router table-SET ON LOW SPEED. I've tried routing balsa with a router bit, but with mixed results. It seems to cut unevenly. I usually bandsaw the parts to rough size first, then sand to final size. Sorry, but that's no help for those who don't have a bandsaw. For Template material, I use Plastic laminate (Formica). You can get free scraps from laminate distributors or cabinet/countertop shops.