Bear,
A while back Steve had a pattern the when put together ended up being a 3-d
human head. I must admit that it would take a boatload of sanding (which, I'm not
a fan of).
Couldn't a pattern be done where it was made the same way and glued together
and then sanded? I would also think a woodturner might have some kind of idea on
how to make one a little easier. Maybe even a combination of woodturning and scrolling
might get the job done.
I will recommend 2 woodturners that might be able to help you. One fella lives
in Eureka, Montana by the name of Ian Jeffcock. to send him a message on Facebook,
type Ian Jeffcock woodturner in the search box. Another guy to contact is Dennis Liggett
who lives in Monument Colorado. Excellent woodturner who I think if it can be done,
Dennis has either done it , seen it done, or knows if it can be done.
What the heck, give it a shot, ya never know.
Mike