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Yes, it's extremely tough to work from scratch with hand tools. I use an angle grinder for a very rough shape and thickness, and then a belt sander to flatten each piece. Once flat, I clamp them together and work on the shape using the sander - that way, I get them even. Only then do I consider doing work by hand. Hats off to you if you're doing it all without power tools! Look forward to seeing the result.
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Will have to try the angle grinder. Most of my tools are automotive so my wood working/cutting tools are hand tools. I am taking pics as I go and will share them when done.
