Before I got my Domino's, I used to just make patterns with 1/2" Baltic Birch. Basically you drill two holes, in line.  Then place them on the table saw and raise the blade to connect the holes. I would then dado a groove and glue in a small fence to register the piece to the wood. Then hawg out some of the meat with a spade bit and clean it all up with a plunge router. Use either a template bit or a collar with a carbide upcut straight bit. The Domino's work amazingly well but are stupid expensive (over $2k Cdn now, I think... fine for a full time gig but pretty pricey if working as a hobby)

Angellos