Captain I like your approach to template.
Here is how I made template for Vero 29. I did not use a scale. For CXB 3590 i was just going to put it on a transparency sheet and use the sharp knife i had.
I just cut it like this. Got a A4 size transparency sheet from Office Depot for .50 cents each and pretty thin. Not sure how much thickness.
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Here is what Not to Do. Use template on heatsink and not the back of cob.
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Here is how cob looks with thermal paste mounted on a transparent sheet. Gives an idea of how a COB sits and uniformity of paste. Note how too much paste was used.not so clean job.
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I align 4 screws
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Artic Silver 5 is thicker so hard to clean template after use. Much easier with Artic MX 4 as it is thinner and easy to clean.
I use IPA to clean the template so i can see screw holes incase they get blocked.
Will consider getting
this to measure exact thickness.
Edit: I use my old insurance card to spread paste. its similar to credit card but thinner.