I've made several sizes of holders. I never could find any plans around on the net, but did find some ANSI standards for riblock placement and T-dimension (surface of holder to film plane) floating around on the net somewhere..might need the wayback machine to find it now. But having the actual back in which the holder will be used will provide all the measurements you need.
Dismantling a holder is excellent advice, really helps to clarify how the parts work together, even the modern plastic ones.
Traditional woodworking tools might be awkward for the tiny slots and rabbets. I use a slitting saw in a mill, 1/32" for the darkslides and septums up to a point, 1/16" is better for septums on the larger holder sizes like 8x20. Garolite XX grade from McMaster Carr is an excellent material for darkslides and septums. Also velvet for baffling and brass shim stock for trap springs are available from the same source. I used Filmoplast tape from Talas Online for the hinges.
I wrote up the last batch I made as a memory aid for future reference, since I make holders so infrequently. I'm not sure if it would be make any sense to anyone else, but it's
here if you're interested.
BTW, basswood is likely way too soft- I've used mahogany and cherry but cherry is probably ideal- grain is tight enough to hold detail in the tiny joints and slots.
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