I found a template on-line, downloaded it and printed it onto A4 size paper, then carefully cut each section out and glued them to a piece of hardboard. (MDF would have been better but this was lying around in the garage).
Once the glue dried there was a lot of creases. The lesson here is to use a thicker paper or light card to print the outline onto, or use a spray glue which doesn't wet the paper too much. I don't think the creases will have too much baring on the final template.
I then used my Jigsaw to rough out the template. I wish I had been a little more confident and cut closer to the line, I have left myself a lot of sanding and filing.
Using a combination of planes, files and sanding blocks I gradually refined the edges to the outline.
Then I applied filler all round the edge, I can get a better, smoother finish once it has dried. I plan to varnish the template once its finished and hopefully use it over and over again.
I was looking around the garage and I found a piece of pine about 1 1/2" thick and 4" wide, I figured that I could build a prototype using the pine for the body (with something laminated on the front to make up the required 1 3/4" body depth). I cut it into 4 equal pieces and then sanded the edges and glued and clamped it all together.
I will let this set overnight and take the clamps off tomorrow after work! Stay tuned for more updates.
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