creating an accurate model of a complex 3 dimensional object without any flat surfaces

[tyR67AJ]

Hi Forum,

The past couple days i've been trying to model a wooden beam for an old car to 3D print it and replace it, but i've gotten into some difficulties keeping the measurements accurate and keeping the shape the same. Does anyone have tips on how to model a object that doesnt have any flat surfaces? My approach was to take a top down view and a side view and then extrude them and use the intersection of those extrusions to create the wanted shape. This gave pretty decent results but Im not sure how to properly edit the ends of the parts as they need to connect together with another part.

Ive linked some pictures below...

 

Thanks in advance!

  

 

[jeffescott]

I would make a template of the parts.   
then select three points on each curve the two sides and the top.   Most likely the inner edge

then I would plot these points in sketch

i would create a two point spline on each of the curves.  
i would the spec the tangent handles at junction between the side and top curves

i would spec the two side splines bottom to match the angle of the template

the adjust the length of the handles to match the third point

i would then create profiles of the piece at each control point and finally loft all the profiles.