A friend of mine needed a replacement leg for a cabinet. He brought me a mock-up which was a cardboard duplicate of the existing leg. I first made a glue-up out of Poplar to match the size needed. I then generated a cad file using TurboCad, then printed out the cad file at a 1:1 ratio. This was then glued to the surface of the previously made blank (with spray mount), and cut out with a band saw.
Finish sanding was accomplished with a Delta Oscillating Sander attachment for my drill press.