I took a 2x4 and cut a bunch of rectangles, and then I sliced them into a via with a saw. You can use a hand saw....but it may take awhile, or you can use a jig saw. And when I say 'you'....I mean...my brother. I've used a jigsaw many times....but it's so much easier to dictate than to 'do.'
I bought some cheap 50 cent paint and painted my cat shape (I (had my brother) cut out all different sizes).
I sanded the edges to give them a little bit more of a vintage look. Then I used these little round brushes to dab eyes. I let the white dry and then went black with the smaller size for the pupil. I'm keeping these simple....b/c they have some friends joining them soon.