update :
i got all the round cuts done. i bought the panels cut, so i didn't have to worry about that.
i built the insert today and 3 panels of the outer box.
i still have to pay a visit next week to a carpenter to get the edges of the half-moon rounded.
unfortunately i got pawned twice

the shop said they had 25mm thickness. upon measuring the panels home, i saw that the mdf was exactly 1inch thick (25.4mm). so now, the insert won't fit inside the outer box. sanding time !
my jig-saw played me a nasty trick. when i tried to do the 45deg cut, the blade wasn't cutting straight and it messed up the edge. fixed it with some glue. i had to do that cut with the handsaw and the use a wood rasp to get it right.
should have build pics soon. i just need to borrow a digital camera.
i still haven't tracked down some plexi. :(