[richs11]

If I were doing this, I'd do as others have suggested and make a template that you can then use with a pattern bit on a router table. I use this method all the time - even for one-off projects. As others have noted, a primary advantage of making a pattern of MDF is that if you screw it up, you can make another. Another significant advantage is that MDF is pretty easy to sand 'with the curve' (unlike plywood, in my experience). So starting with 3/16 or 1/4 inch thick MDF and either a scroll saw or band saw, that'll get you pretty close and a sanding drum/spindle sander would be the next step to get pretty close to the pattern. Then hand sanding along the curve will make it smooth - let your fingers (close your eyes...) tell you whether the curve is smooth. I suppose you could try 1/8 inch thick MDF, especially if you are only making one. In that case, then once you get the curve(s) smooth, you could coat the edge of the template with a layer of polyurethane (don't use water based...!). I have read this suggestion elsewhere - though I haven't tried it - it has the effect of strengthening the edge of the thin template (which might otherwise be thin enough that it could compress a bit on the edge).