You are right on the way to approach this and the type of wood to use although finding the wood in a small sheet will be difficult but you could try Home Depot for one of their handy panels. As far as holding them together I would use double sided tape.

 

Art, I am not aware of any HD stores in Greece.

Dimitris, plywood is commonly used for projects like this. Double sided carpet tape is used by many many woodworkers to hold pieces together as you describe.

 

I would use a scroll saw.

 

Well Mike is right. We have no HD, but we have some similar bigish stores that sell averagish quality sheets.
From actual wood, they usually have only beech and spruce.
Other than that, they have mdf, plywood and various laminates.

And yes Mike that was a nice point. I am leaning towards plywood for them. I will try to find some carpet tape, although with the economy BS right now, it is getting difficult to find stuff...

About the scroll saw, I guess it falls in the same category as the jigsaw. Nice for the job but the sides will require further finishing.
Plus, i do not consider it the safest of tools for that kind of repetitive job

 

I would use luan plywood and stick it together with double sided carpet tape it works well and comes off clean. I have used it several times with templates with no problems.
Have a great day.
Roxanne

 

Hi Guy. This may seem a bit convoluted, but I did it on a project and it worked fine. I, too, had to make multiples, and leave a clean surface. I made a jig out of 1/2" cabinet grade plywood, then used the smallest clamps I had to clamp the jig, on top, to the three pieces of rough cut (on a bandsaw). The clamps projected about 1/2" below the bottom piece, so I used some double stick tape to secure a piece of 3/4" plywood right in front of the router bit coming up through the table. I used a 1" long bit with a bearing end, and adjusted it up to the correct height. Then as I made my cut, as I got to a clamp I simply removed it for the time it took to cut out that part, and then replaced it after the cut was past. I used four clamps, and the other three kept everything together just fine. The jig took the longest time to make, and that was a simple carbon paper tracing onto the 1/2" ply. Sanding the edges gave me a nice smooth jig.

 

Convoluted, maybe; but it has my vote. I hate double sided tape, always had a terrible time getting the wood clean after, the few times I used it. Some people swear by rubber cement, but I have the same problem with that as I do double sided tape. Now I just tack my patterns down with short thin nails. If your sister is going to glue these pieces down, it wouldn't matter if there were nail holes in one side, just glue that side down.

I get nice smooth cuts with my scrollsaw, maybe it depends on the blade used. Personally, if there were a lot to be done, I'd just tell my sister to use my scrollsaw and cut away.

 

I though about something like that, but this might require pre-cutting the plywood to allow the cutout to be clamped... I will try it

 

Use thin plywood, stack up to 3/4 inch thick. pin nail the stacks together in the waste area or tape them together with packing tape. Get some Flying Dutchman Scroll Saw Blades and using a scroll saw, cut them out. The scroll saw leaves a cut that needs little or no cleanup and is one of the safest mechanical wooodworking tools available.
GG

 

I would also agree with JOAT and Grandpa. I've stack cut Christmas ornaments and cut on the scroll saw. Small brad nails or hot glue in the scrap area. Baltic Birch ply is probably the way to go if it's available.

If you use plywood, no matter what you use to cut them out you'll have some sanding to do.