If you can get a side shot of your digital file and also the front rear and top you can literally paste them onto your mdf block or whatever your using and start to carve it out that way.
There will be companies that can make it for you. Approach people how make parts for motorbikes or boats, or anyone that uses fibreglass / carbon as they'll know how to mould it properly.
Once you've done it you need to prime it with a high build primer and then flat that down and probably prime it and flat down again for an ultra smooth finish.
I've got some contacts still if you can't get any where, not sure what they'd charge, give me a PM if you want a hand.
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