garageFab.cc

This is the method I used to create contraptor components.  I invented this method because Vitally's method of printing templates did not work well on my printer.

Using this method you will need:

•  Drill Press
• Vice Clamp
•  Ruler (or some form of measuring device)
• 1/4 Drill bit
• Razor Blade

Directions:

1. Get the right angle material and measure 1/2 inch from the edge.  Score a line with a razorblade.
2. Do the same for the  opposite direction.
3. Using the drill press and the 1/4 drill bit allign the + that you made with the tip of the bit.  **HINT: you can "bump" the drill bit up and down to see if the very point is on your intersecting lines.
4. Drill the 1/4 holes when all is alligned.
5. Using this piece as a template place this part in your vice clamp.  Remember that depending on the clamp YOU use this will affect your placement.  You need to get the hole alligned up so that when you bring down the drill bit it will slide without touching the walls directly into your existing hole.  Note I setup this process so that my angled piece was flush with the end of my vice.  This made it very simple to know that I was in the right spot.
6. At this point you should have everything tightened down so that all you need to do is place the material in the vice and drill each piece.  Remember that this will only allow you to drill the ends at the moment and only 2 out of the 4 holes. 
7. To drill the other two holes, once ALL your material is has 2 holes in it you basically just do stepts 1-6 all over again but this time alligning so that you have the opposite holes to be drilled.

I know this was very wordy but check out this video for a visual explaination. 

EDIT:  I added another video to show more information on this method its here.