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Someday I will build one of these…
http://woodgears.ca/bandsaw/homemade.html@ed For the male connectors, the best idea I can come up with is a coping saw. The dowel method posted seems quite promising as well.
For the grooves, in the link I posted, the user makes use of a flexible saw flexed against a curved template. Two cuts are made and the waste is chiseled out with a narrow chisel. Scratch stock might be the approach that requires the least amount of jigging though.
I came across this article (while reading about hammers): https://www.popularwoodworking.com/woodworking-blogs/editors-blog/sawing-curves-with-a-straight-blade-saw
I have had this issue. It seems like the previous owner ground the edge of the cap iron too much and basically leveled the front edge of the cap iron with the rest of the cap iron. Thus, there was insufficient pressure being applied to the cutting iron and I had a lot of issues planing.
You could try to bend the cap iron to get some of that tension back, but I have not tried. I ended up buying a new cap iron.
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