The start

Well, I dont have a large format printer, so I layed out a grid on a piece of Masonite (1/8") and using SketchUp, I figured out the profile to the nearest 64th of an inch. Then on the masonite, I used a digital calipers to transfer the profile.

I cut out the profile on the bandsaw. Four pieces of 3/4" plywood are screwed together the outline traced onto the top piece. Then took this good awful heavy 3" x 10" x 40" chunk of wood and started cutting out the profile. Below is the result

Its a lot lighter now. Now I have to find a spindle sander to smooth the inside surface. I have left hints for Father's day. We'll see.