My temptation is to use 4mm static cord... Its plenty strong even accounting for wear and loss of strength from binding around things... And its a little easier size to use/handle than the finer ones...
I use diamond tips on my dremel they come in inexpensive sets of a bunch of shapes and work well on everything. The outside large curves will shape faster with a good sized file than with a dremel. I work on stuff like this while watching TV... So time is less critical than noise. Use a small saw to get close in cutout.
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