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Well, It seems to me you can either increase the size of the blank or slightly decrease the size of the pattern. Most printers will allow you to increase or decrease the size of you printing job.
I had considered useing a hot glue gun but I like to be able to reuse some of the bigger waste pieces. Also when I use brads and they extend through the bottom piece I am always carefull to take a small hammer and tap the points back up flush with the bottom piece so I do not scratch the table.
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