A variable speed band saw will work very nicely to cut the tender. Also, you can use a micro saw blade in a Dremel tool set to a very low speed. This is a minature saw blade, typically between 1/2" and 1" diameter, and really, really thin. I don't know if Micro-Mark sells them or not. I got mine from a train show a few years back.
As for filling the gap, the thick CA will work, but is difficult to sand smooth. I'd recommend something like either Bondo (the stuff used in automotive bodywork) or "Squadron Green" putty, which is available from the hobby shop. These putties are much easier to sand and work, as that's what they're designed for. I'll use CA when filling gaps in something that's supposed to simulate wood, because I can use a coarse sandpaper to sand things down, and the scratches will blend in with the wood grain. For a tender side where you definitely want a smooth surface when all is said and done, you'll want to use a proper putty.
Later,
K
As for filling the gap, the thick CA will work, but is difficult to sand smooth. I'd recommend something like either Bondo (the stuff used in automotive bodywork) or "Squadron Green" putty, which is available from the hobby shop. These putties are much easier to sand and work, as that's what they're designed for. I'll use CA when filling gaps in something that's supposed to simulate wood, because I can use a coarse sandpaper to sand things down, and the scratches will blend in with the wood grain. For a tender side where you definitely want a smooth surface when all is said and done, you'll want to use a proper putty.
Later,
K