Getting one for your 500 shouldn't be difficult as that is something that won't have a super fine feature size. Fine tuning will likely solve some of your brightest star problem as I do just point it at the brightest star I can find and haven't had an issue. I have at times not paid close enough attention and used a planet (usually Jupiter or Saturn) which results in a mess when trying to focus with a bahtinov mask.
As far as making masks go I
create the template on this site and get an SVG file. I usually try to have as many slots as I can cram in to get more light to the sensor so I play around with it for a while. As far as the range the function over if you have one optmized for one focal length it will work for ones down to about 1/2 that length but the results will gradually get worse. The one I have for my 300mm I can use on my 135mm and it is useable and on my 100mm it is barely functional. After that it is totally worthless. The one for my 400mm I've used on the MTO 1000 f/10 with 2x converter to get the focus correct and going up seems to allow for better leeway of usage. However for small lenses you may find the slot width to be too thin to create with what is available to you. I'm trying to get one made for my 50/1.2 but I need access to a laser cutter.
As far as what I usually do after getting the SVG I typically
use this site to cerate an STL file by extruding the SVG file 3 to 5 mm depending on how big I am making it. For my 400/2.8 I needed a big one so made it 5mm thick, but for the others I went with 3mm. Then I have just brought the STL down to the library to use their 3d printer to print one out.
The problem with 3d printers is that any that a normal person has access to won't do well with slots much narrower than 1mm so for masks for short lenses you need some other option. One thing I've thought about is laser printing onto transparencies but transparencies one can send through a laser printer are really expensive for something that I am likely to use just one of so I haven't tried this.