i have interest in a 16 DIP relay PWB as well, so i laid one out.
the design guidelines:
* use dougs 3/32" turrets.
* DPDT relay that doug sells.
* use mill-max sockets.
* try for under 2" x 2" board dims. we have 2" x 1.5" with 1.5" x .75" mounting centers.
* 4 post mounting utilizing 4-40 fasteners.
in order for us to use dougs turrets, we must specify 125mil thickness PCB material and this drives the cost up considerably - about 2x that of 62mil or 93mil material.
hole finish tolerance is usually around +/- 5mils and varies from mfg. to mfg., so you'll need to make allowances. i used a 94mil hole for the turrets - the turrets fit into a 3/32" hole which is a 93.75mil hole so it's gonna be close if you stick with the pattern presented. you may wish to specify a #40 or #41 hole size for the turrets if you want a for_sure_fit. better still would be to leave the board un-plated (no tin/solder finish) and just have a solder mask over raw copper with unfinished vias. it's trial and error based on the board house tooling, etc.. get a couple made, test fit, adjust if needed, accept or repeat, then order quantity. if you change board mfg. then the tolerances will change.
the easy way out - make hole 5mils overbore, then stake and solder - worst case is turrets swim in 10mils of air slop; best case turrets fit like a glove. no worries because solder keeps things tight.
if cost is an issue, specify 62mil PCB material, no solder mask, no silk-screen, no plating, and use dougs 1/8" eyelets for 1/16" PCB material thickness.
PM me if you are a member and would like a copy the gerber RS274X files and NC drill file.
--DL