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I often make them in 5mm ply or thin MDF, sometimes start with a paper template and transfer it to thin board. It's still a job with a saw and plane to get a really good fit. The transfer stage gives you a chance to tidy everything up once you know it fits.
It helps if you plaster the walls flat and sloping in slightly each side! Looks like the decor is already done though.
Sometimes you can chisel a channel for the board on either side and fill to the face of it. The join shows less there than it does on the board face.
Airhead
@Polygon
How should I be scribing a new cill (I already have it) to fit in here? Scribe on to scraps of plywood, cut them out and then use them to scribe the line back to the cill?
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