This is the final product of our interconnected wall experiment, minus the interconnecting bit.  Due to time and access to the router this was the most that could be completed.  The process after it was cut on the router involved many layers and was very time-consuming.  The piece was cut twice, the front and back, these portions were glued together to achieve a two-sided form.  It was necessary to cut out the holes by hand and then sand smooth, for a clean finish.  Any notches or uneven edges were spackled, sanded, and then a final coat of paint was applied.  It was framed with pine 1×4 and trim, the whole frame was stained and a final coat of polyurethane was applied.