Something that looked pretty funky to me was a recent (but still expired) discussion on the MIMF about cutting the inner portion of the arm rest on a bandsaw.
Basically, the person (I forget who it was) made a block the shape of the armrest portion, fitting it perfectly to the inside of the side first. Next, he tilted his bandsaw table to his preferred angle (wasn't 45 degrees, but I can't remember what it was exactly), and freehanded the curved, angled bevel section, leaving a 'flat' gluing area about the size of normal lining. Basically cutting the corner off, and 'fairing in' the edges, a la Laskin. Finally, again using the bandsaw with the tilted table, he sliced off a roughly 1/4" (or so) slice off a section that's pretty much finish-shaped, fits perfectly (except for some dish sanding, perhaps), and is only as thick as it needs to be all the way through, meaning it's as light as it can be.
Took a few practice pieces to get right, apparently; once you've made the first one, that can be used to template rout other blocks, I suppose.
To me, that looked like a very, very elegant method of doing it all. Still doesn't address the issue of binding and purfling, but your pre-glue solution would be applicable here as well, I'd think. I've been fiddling with this question on paper for a while now, because I'd like to build a guitar with one at some point, and while the top ledge binding seems not-too-evilly-complicated (not too hard to make a guide to follow. Fidlly, but not impossible), but the side mostly just seems like it would require cutting by hand, carefully, with chisels.
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