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I get my pins and washers from a local hobby store (Hobby Junction, Dorval). I'll be making an order from microfasteners soon though, it works out to be cheaper in the end. PM me if you want to split...

I use the same process, except I use a scroll saw, not a band saw. I also use a 1 1/2" Sanding drum on my drill press instead of a belt sander.

You get your wood from Langevin & Forest?