WB1 of 4...my project as of now:

The website explains most of it, I used a CNC machine to mill this out, I also plan on using 1/2" plexi, milling out the reverse image of the design into the plexi, the depth would match the thickness of the gasket. I also plan sandwitching the gasket between the two wood boards shown and then milling the design out so the gasket will go over the channel dividers as well as everything else. It takes 6 hours to do one block, and it has to be strait since if you move the block after it's set in the holder you loose all the precision. I'm still deciding what to do for my last two designs, if you got any ideas let me know

http://www.geocities.com/ajrettke/WBS.html
(notice the 1500 grit sand paper for lappin

This is what I get:
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looks VERY nice!!!