Actual thickness is 0.196". That's slightly over 0.1875" (3/16"), but they call it 1/4", LOL!
I cut the parts out with the Trio, a cutting bit & a straight-edge.
1 Back: 10"h x 12.2"w
2 Sides: 10"d x 12.4"h
2 Top/bottom: 10"d x 10.2"w
Notice the back height is equal to the depth of the other parts - all are 10". This is one less adjustment or measurement to make when ripping the parts.
I used the 1/4" straight bit to make the groove for the back which is slightly wider than the plywood. But I'll fix that later.**
|I cut a 1/4" groove in the top, sides & bottom. I cut the groove half the thickness of the plywood, about 3/32" deep, & about a 1/4" from the edge.|
Using the chamfer bit I beveled the edges of the same 4 parts.
|Dry fitting sides, top & bottom around back - which is fitted into groove.|
|Back fitted snugly.|
|Dry fitted front. (showing masking tape holding box together)|
|Make sure the grooved side of each piece is aligned to the straight-edge. Then with masking tape tightly apply the tape while pulling the parts together - keeping them aligned to straight-edge.|
|Carefully flip over the assembly. Notice that the grooved edges are all aligned at the bottom.|
|Apply glue to all the bevels & grooves.|
|Close up of glued areas.|
|Fold the sides, top & bottom around the back & tightly tape the top & side to complete the box.|
|Wipe off any glue squeeze-out.|
|All seams cleaned.|
|Turn the box with the back facing up & **apply weight to the back to push it down to make it tight & flush on the inside. Remove the weight only if you're using clamps ** |
I clamped all the sides & put some extra tape here & there.
|After the box has dried - glue & tape down the front trim.|
|Box almost finished - just need to check for any gaps, if so I'll need to do some filling & a bit of light sanding.|
Not too shabby for lauan!
A sliding plexiglas front could be fitted at this point, but I think I'll do a storefront instead. It will fit snugly & will be removable.