> Lots of options here, so I need to start experimenting.
> The curves will be fine, and I intend to make a jig.
>
> The options I have are now many:
> - Heated wire -- need to locate proper wire.  Power
>         supply etc is easy to get, but will need to
>         experiment with settings.

Don't bother - hot wire doesn't remove waste and you'd
need the wire insanely hot to make any progress, with
the added side-effect of monomer fumes. I tried it once
and what a messy job it did. The cut will seal behind the
wire even worse than a bad blade and the molten plastic
makes a ridge. Hot wire is only suitable for a limited
range of materials, like polystyrene foam

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