Yes, I realize this is an old thread. But as I argued in another Pinside thread -- why not keep like stuff in the same thread? Why not refresh the thread rather than having twenty threads scattered all over dealing with the same thing? Yes, I understand how Google Searches work.
I finally came up with stencils that I am happy with. These are for Gottlieb Totem, and they are solid, will be reusable, will allow for the overspray (if you wish to do it like it was done in the factory) and here they are -- one for each color for the sides and one for each color for the front. The purple side color includes the cutouts which need to be sat in place while spraying. The stencil edges will all be clear-coated to give them long lasting rigidity that the wood would not have on its own.
1. I used a roll of vellum tracing paper to carefully trace the entire design, separate vellum tracing for each color
2. Then I cut out sheets of 1/8th" panel plywood to the exact size of the machine sides and front
3. Next I used removable adhesive and sprayed the wood, for each panel and color, laid the vellum sheet down and aligned it properly
4. I used an Xacto knife to cut out the shapes from the vellum, leaving the wood exposed
5. I used a fat drill bit to drill a single hole in each shape (giving me room for a jigsaw blade)
6. Using a flexible speed metal blade, I cut out all of the shapes (saving the purple insert shapes -- as per picture)
7. On the side pieces, because they are long and now have many holes in them, I added a lower and back 1x2 for support
8. Finally, I labeled them with a marker, so there would be no question which stencil they were, and no issue with where to align them on the cabinet when it came time for painting.
Gottlieb Totem - Front Cabinet Stencils.png
Gottlieb Totem - Side Cabinet Stencils.png