Cutouts for accessing and viewing the inside of the top case were routed out of the side panels. I was able to re-use two router template jigs for the cutouts, although one had to be mod'd to reduce the width of the cutout.
Threaded inserts were installed in order to attach removable plywood covers over the cutouts.
My next task is to build a shelf to fix that droopy motherboard tray.
I managed to spend a few hours in the shop this morning working on fastening the top divider to the case itself. But just like everything else on this case, nothing is fastened permanently, which meant I needed to install some more threaded inserts.
The divider is attached to the side panel's solid oak rails:
Even the most mundane aspects of a build often require many small steps in order for them to come out just right. For example, in this build the fastening of the side panel covers required having to accurately transfer the locations of several threaded inserts to the covers, which was accomplished by first screwing in some button head screws into the threaded inserts.
Followed by taping a cover perfectly centered over the cutout. And then using a deep throat clamp, transfer an impression of the button head screw into the backside of the cover.
Lastly, with all of the fastening and unfastening of bolts into and out of the threaded inserts, some of them started to become loose. After testing many types of glues, the best method for fixing the loose threaded inserts was to flood the area with Cyanoacrylate glue. Blue painters tape with punched-out holes was used to prevent getting glue everywhere.
I've been working on the case doors, which has been a time consuming task consisting of cutting the 6.2mm-thick oak veneer plywood down to a rough size and then thickening them by gluing strips of 1/2-inch thick birch veneer plywood.
The panels are trimmed to their final size (less 1.5-inches) and then 3/4-inch square solid oak strips are glued to the edges of the panels to hide the plywood veneers.
With the fabrication of the lower case essentially complete, its on to finishing...sanding, staining and applying wipe-on polyurethane. With a large piece like this, its essential (for me anyway) to be able to apply finishes comfortably, which I can do sitting down by using a homemade turntable.
The turntable is just the undercarriage of an old office chair.
This week the window in the doors were routed out. Then the doors were scraped, sanded, stained and finished with a satin wipe-on polyurethane finish. Here's what a door looks like after three coats of polyurethane:
In between staining and finishing the parts to the top case, I worked on fabricating the front doors using the same build techniques as all of the other doors in this project. The final width and height of the doors was gradually achieved by numerous trips to and from the jointer.