Subject

What you are trying to do is very similar to what is done to make stamping
dies for gaskets.

I'd probably approach this as a two (2) part product consisting of a piece
of 1/4" plywood and the 3/4" finish material.

Recess the plywood into the bottom of the piece, then layout the lines and
use a scroll saw.

Wedge some "bridges" into the saw cut at the appropriate locations to
maintain registration while you do the glue up, then remove them afterwards.

A flying red horse at 1,000 ft will never see that it is a two (2) piece
construction.

HTH


--
Lew

S/A: Challenge, The Bullet Proof Boat, (Under Construction in the Southland)
Visit: http://home.earthlink.net/~lewhodgett for Pictures