Thanks for posting your app intealls. I'll print out some templates soon and try it on my g80. For now I only have access to manilla folder type cardboard but if that works well then I'll move on to something better. What kind of material are you going to try next?
I've been trying lots of stuff the last few days, foam rubber, ordinary printer paper (multiple layers of it), stiffer paper, thin foam etc. My index finger is seriously worn from all the cutting.

I found the foam rubber I used to be too thick (sheet was about 2mm) -- the effect is probably similar to the sorbathane ripster used. It also shortened the travel a bit too much for my liking.
Right now I actually prefer two layers of ordinary printer paper. Since the paper is very light, it doesn't matter if it hovers 1-1.5 mm above the switch when being pressed down, I can't feel a difference if it's flat against the switch or not. Of course, printer paper is not very durable. :/ I'll have to use it for a while to see how it holds up.
Next I think I'll try to get ahold of some rubber sheets, between 1-1.5mm, and some kind of soft cardboard (between 120-180g? I found 240 to be a bit too stiff). This whole thing is seriously addictive.

Post your results and tell me if you need help with the app! Also make sure to calibrate the printout, and measure the final print that you're about to cut against a known value. Cutting all the squares just to find that it doesn't fit on the keyboard is, well, disheartening to say the least.

Also make sure to recalibrate when using a new kind of paper, my printer skewed differently depending on what paper was used.