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I used a 3 mm drill bit to make the holes. I don't know what would be the best dimension for laser cutting. Perhaps you could try different sizes and see which fits the best?
No way! That's super cool, man! Well done!
3D files and templates can be found here:https://grabcad.com/library/automaton-mechanical-p...I suggest you open the 3D assembly file and look at which part goes where. It's a bit tricky, but totally doable.
Looking good! :-D
I made the Pikachu automaton by printing out the part drawings, gluing it on a piece of plywood, and then cutting it with a scroll saw. No issues with the assembly.