I have used the method that Kit suggested. I cut straight sides with a 1mm cutter to refine the edges after pocketing out the piece with a larger cutter. the 'veneer' was cut mirror-image out of 8mm thick stock, and I think I went down 5mm. When I put the two together it was an interference fit, so I planed down the excess with a pocketting program and sanded to finish.

If you plan your work so that all corners are radiused 0.5mm, you should get a perfect fit. I did consider glueing, but the french polish held it all together nicely.

Sorry, but I can't find pictures of the finished job and the work went out as presents.

Cheers,

Rob