I think that, assuming you lack laser cutting or CNC equipment, there is no way that you will be able to make something that looks as good as the default
40K templates (which, I hasten to add,
cost less then $5 shipped)
I would suggest
this alternative template if green doesn't work for you.
I know there was a guy here to did do laser-cut acrylic stuff, but I think he may have gone out of business in a thread I saw. Not sure about that.