Yes the 0% DSA is alot of work, it took me along time I did it with handtools. the mag well was the easiest, again I just used a drill press and drilled out the center its alum.
yes doing the buffer threads by hand is tricky, I know I did it. if you have a 80% tannery or a FFL 100% then you can use that as a templete. if this project is to much work then by all means get a 80% and spare yourself. I used a caliper for this and everything came out decent
when I am at the range I like showing people were the drill cut a little deep in the magwell it amazes them that it was done with hand tools
I have a couple pic's of construction and use of my DSA 0%, if you send me a PM with a E-mail address I will forward them.
my jig is on loan I maybe tempted to rent it around for a fair rental fee including the die for the buffer
tools I used were drill press, dremel, old sear's cord hand drill, rat files, large flat file, caliper and good plans
if your a member at Roderus the plans are there free, plus a few build tutorials including anodizing plans (these guys have got this down), I send out my alum to be anodized its cheaper
hay goodluck guys, if I can help or give advice feel free. I did my build in 2000, starting my last sig 228/229 alum 80% frame with hand tools!