Quote Originally Posted by jbkuma View Post
It's really not that hard to make it extremely accurate with this method, you should be able to make a very precise representation. You can very easily print and test fit it to make sure before you go into design. Your measurements can very easily introduce just as much or more margin. Using any other method, even a 3D laser scan,j has some margin of error. You'll also have a margin based on the medium you transfer your design to. The thickness of the medium can easily tweak your alignment as much as anything else.

You can scan, trace, print, and test fit in less than 15 minutes if you have any experience in illustrator. Tweaking it, if necessary, should take less time than this discussion.
I'll let you know how it goes