| I haven't worked on a saddle such as you describe. I did replace the saddle in my Applause ABG. As you suggest, I kept the original intact; I ordered two blanks of Tusq replacement material from Stew-Mac and use the original as a template. Personally, I'd skip the wood strip on the bottom and just use the saddle material.
Sanding the bottom can be done by gluing sandpaper on a sheet of plate glass or marble, then using a 1x2 or 2x4 as a straight edge and sliding the piece along the side of the wood to keep the base square. Shaping the top of the saddle will require more handwork. I did most of the top curve on mine with a disc sander on a Shopsmith, but that's a bit risky on the fingers. Don't know that I'd be that brave (or stupid) again. Files work pretty darn well.
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"Ya know what old Jack Burton sez at a time like this? Old Jack sez....'what the hell.'"
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