Search:

More than anything I think it was the sand paper that got the job done. My arm was useless for quite some time afterwards and I was really sore the next day.
Thanks for piping in :)

This has been a lot of work, but a great learning experience.
I started out with this (yes I bought the handsaw just for this task :))
The slab of wood I believe is Koa (bought from a knife maker)...