T-slot cutter does sound like the way to go, I'm trying to see if I can find someone with a milling machine I can borrow.
Has anyone had any success with using cheap AVR programmers to hack the TZ85As? (Such as this: http://www.ebay.co.uk/ulk/itm/252087015960 ) The polulu one is pretty expensive and kinda defeats the point of hacking them yourself.
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