The fasteners were sourced from a local hardware store and modified w/ a hacksaw, a wire crimping tool which was just the right size to hold them, and a file.
The holes and outline were cut using a CNC following G-code output by MakerCAM (a fork of the Flash file PartKam).
That was a _long_ time ago, and the free software has gotten much better/easier, and these days I work for a company which makes integrated software for the CNC machines which we sell.