Hey that's kind of a cool idea. That brings to mind this type of puzzle-piece construction. You can start saving for a computerized saw Otherwise I would probably cut one side to the pattern I wanted and then scribe the other part and shave it until it fits. Wrap the $#&@ out of it with reinforced tape to pull the joint together... or it can be hard to work with thin little strips so you might consider doing it to your larger boards before they get ripped.

That type of work can be done... but it ain't easy.

- Chip
http://www.ChipSandresky.com