Build the large deep-substrate hinged enclosure

1. Qualify the support and service position — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use a qualified level rigid support under the complete finished underside, at least 72.092 in (1831.14 mm) wide × 36.092 in (916.74 mm) deep at the maximum skin. Every edge bears continuously; the guide does not design a stand or qualify the building floor.
2. The conservative bed envelope is 24.13 cubic feet (683 L), before framing displacement. At an assumed wet bulk density of 100 lb/ft³ (1602 kg/m³), the bed alone would weigh 2413 lb (1095 kg). Add the shell, water, rocks, furnishings and equipment when qualifying both furniture and building floor.

Check before continuing: Qualified full-footprint support and the complete load assumptions are recorded before construction.

Exact workshop reference · Show this stage in 3D

2. Qualify the support and service position — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Keep at least 32 in (812.8 mm) working space in front, 6 in (152.4 mm) beside each door swing, complete roof access and at least 2 in (50.8 mm) above each opened leaf for lift-off. The side captures make reference width 72.811 in (1849.4 mm). Allow separately for the real hinges, hasps, tools and handling.
2. Place and stabilize the empty enclosure at its final location. Provide furniture restraint appropriate to that support and wall where tipping is possible. Never stack, suspend, climb on, lift or tip the loaded shell.

Check before continuing: The entire floor is supported and the load and cleaning routes have been checked before construction.

Exact workshop reference · Show this stage in 3D

3. Receive and measure all materials — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Measure the actual plywood thickness at several points. Check pine is 3/4 in (19.05 mm) thick and solid wood supports are 1 1/2 in (38.1 mm) square. Reject warped, split or damaged wood and knots at joints.
2. Receive all six LSX-100 lift-off hinges, both N305-979 hasps and their exact screws. Compare their hands with the hinge drawing: fixed pins point upward, moving sockets are above. Confirm all three hinges on each jamb have the same hand. Three LSX-100R serve the left door; three LSX-100L serve the right. Confirm actual head seating and full bearing before drilling. H01 remains open until received hardware and the trial are accepted.

Check before continuing: Actual wood gauge, all six matching handed hinges and received materials are recorded.

Exact workshop reference · Show this stage in 3D

4. Receive and measure all materials — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Measure the actual 0.22 in (5.59 mm) acrylic, two separate uncompressed 1/16 in (1.59 mm) neoprene face pads, cured contact films and compressed underlay/liner sample. The bare spacer reference 0.351 in (8.92 mm) leaves a 0.345 in (8.76 mm) finished cavity after two 0.003 in (0.08 mm) films. The 0.08 in (2.03 mm) compressed underlay plus 0.045 in (1.14 mm) EPDM reference totals 1/8 in (3.18 mm); these are not delivered measurements.
2. On a spare strip, mark the floor underside. Above it, mark the actual plywood thickness plus compressed lining to locate the finished floor. From that mark, measure up 18 in (457.2 mm) for the maximum bed, 20 in (508 mm) for the retaining-panel top and 21 in (533.4 mm) for the vent bottom. Transfer these marks to the build.

Check before continuing: All materials and handed hardware are identified; actual plywood and compressed lining thicknesses are recorded.

Exact workshop reference · Show this stage in 3D

5. Cut and identify the plywood — 1

Parts: P01, P02, P03L, P03R, P04, RBL1, RBL2, RBL3, RBR1, RBR2, RBR3

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Support both sides of every cut and use eye/hearing/dust protection. Never reach across a running blade.

1. Follow this build’s 5 current plywood-sheet layouts. Square and label each sheet; floor P01 and roof P02 finish at 72 in (1828.8 mm) × 36 in (914.4 mm). Keep 1/8 in (3.18 mm) saw-cut waste between rough blanks and support both sides of every cut.
2. At the 45/64 in (17.86 mm) plywood reference, each side finishes at 36 in (914.4 mm) × 46 19/32 in (1183.48 mm) and the back at 70 19/32 in (1793.08 mm) × 46 19/32 in (1183.48 mm). Fit sides between floor and roof and back between sides to preserve the 48 in (1219.2 mm) bare height. Use the actual cut layouts, rough allowances and grain directions.

Check before continuing: Floor, roof, paired walls and back are labeled, square and fitted to the actual plywood gauge.

Exact workshop reference · Show this stage in 3D

6. Cut and identify the plywood — 2

Parts: P01, P02, P03L, P03R, P04, RBL1, RBL2, RBL3, RBR1, RBR2, RBR3

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Support both sides of every cut and use eye/hearing/dust protection. Never reach across a running blade.

1. Cut two matched sets of three retainer layers, RBL1–RBL3 and RBR1–RBR3. Each finished layer is 29 47/64 in (755.25 mm) wide × 16 5/8 in (422.28 mm) high. Keep widthwise grain, 5/32 in (3.97 mm) bare side gaps, and unveneered sealed bottom/receiver bearing faces.
2. Label every part, its inside face and its measuring edge before cutting. Use inch markings throughout each cut; metric values are rounded equivalents. Sizes marked “about” are starting marks. Leave the line, then fit each piece to its actual adjoining parts before the final cut.

Check before continuing: Paired side panels and all six retainer layers are square, labeled and matched.

Exact workshop reference · Show this stage in 3D

7. Cut the roof openings and side vents — 1

Parts: P02, P03L, P03R

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Mark three 18 in (457.2 mm) × 28 in (711.2 mm) roof openings, with left edges 5 in (127 mm), 27 in (685.8 mm) and 49 in (1244.6 mm) from the left and front edges 4 in (101.6 mm) from the front. Keep both 4 in (101.6 mm) webs intact.
2. On each side, mark an 18 in (457.2 mm) × 4 in (101.6 mm) vent starting 9 in (228.6 mm) behind the front. Its bottom is 21 in (533.4 mm) above the finished-floor mark, not above the panel’s lower edge.

Check before continuing: All three roof and both side-vent outlines match this build and its finished-floor datum before cutting.

Exact workshop reference · Show this stage in 3D

8. Cut the roof openings and side vents — 2

Parts: P02, P03L, P03R

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Drill starter holes inside the waste and use a guided router or supported jigsaw. Stay inside the corner lines, ease the reveals and remove all splinters.
2. Dry-place the capture strips and check their screws land in solid wood outside each opening. The inner reveal stays smooth; the outer strips capture the cut wire edges.

Check before continuing: Vents begin 3 in (76.2 mm) above the maximum fill; all roof borders and both rib webs remain.

Exact workshop reference · Show this stage in 3D

9. Prepare the frame stock and thin strips — 1

Parts: CLB, CLU, CLT, CRB, CRU, CRT, CB, CT, CM1, CM2, CR1, CR2, F0L, F0M, F0R, F0BL, F0BR, F0TL, F0TR, F1L, F1M, F1R, F1B, F1T, F2L, F2M, F2R, F2BL, F2BR, F2TL, F2TR, F3L, F3M, F3R, F3B, F3T, RCLL, RCLR, RCRL, RCRR, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, RTLF, RTLA, RTLL, RTLR, RTMF, RTMA, RTML, RTMR, RTRF, RTRA, RTRL, RTRR, DL0L, DL0R, DL0B, DL0T, DL1L, DL1R, DL1B, DL1T, SPLL, SPLR, SPLB, SPLT, BELL, BELR, BELB, BELT, DR0L, DR0R, DR0B, DR0T, DR1L, DR1R, DR1B, DR1T, SPRL, SPRR, SPRB, SPRT, BERL, BERR, BERB, BERT, LCL, LCR, LCFJ1, LCFRL, LCFPL, LCFRM, LCFJM, LCFML, LCFPR, LCFRR, LCFJ2, LCB1, LCB2, LCB3, LCPL, LCP1, LCP2, LCPR

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Plane broad supported stock first; never feed short thin strips alone.

1. Follow current PINE-FRAME allocations for all 24 fixed-frame pieces and sixteen door pieces from straight 3/4 in (19.05 mm) × 5 1/2 in (139.7 mm) × 96 in (2438.4 mm) stock. Rip scheduled 3 1/2 in (88.9 mm) broad strips with guards, push sticks and supported stops, then crosscut each labeled piece; preserve 1/8 in (3.18 mm) saw waste.
2. Use current SOLID layouts for every named 1 1/2 in (38.1 mm) square support, four full-height rear uprights, two roof ribs and four short panel receivers. Keep full solid section and square bearing faces; no laminated substitutes are assumed.

Check before continuing: Named supports and frame blanks match their stock allocations and grain direction.

Exact workshop reference · Show this stage in 3D

10. Prepare the frame stock and thin strips — 2

Parts: CLB, CLU, CLT, CRB, CRU, CRT, CB, CT, CM1, CM2, CR1, CR2, F0L, F0M, F0R, F0BL, F0BR, F0TL, F0TR, F1L, F1M, F1R, F1B, F1T, F2L, F2M, F2R, F2BL, F2BR, F2TL, F2TR, F3L, F3M, F3R, F3B, F3T, RCLL, RCLR, RCRL, RCRR, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, RTLF, RTLA, RTLL, RTLR, RTMF, RTMA, RTML, RTMR, RTRF, RTRA, RTRL, RTRR, DL0L, DL0R, DL0B, DL0T, DL1L, DL1R, DL1B, DL1T, SPLL, SPLR, SPLB, SPLT, BELL, BELR, BELB, BELT, DR0L, DR0R, DR0B, DR0T, DR1L, DR1R, DR1B, DR1T, SPRL, SPRR, SPRB, SPRT, BERL, BERR, BERB, BERT, LCL, LCR, LCFJ1, LCFRL, LCFPL, LCFRM, LCFJM, LCFML, LCFPR, LCFRR, LCFJ2, LCB1, LCB2, LCB3, LCPL, LCP1, LCP2, LCPR

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Plane broad supported stock first; never feed short thin strips alone.

1. Plane broad supported stock to 3/8 in (9.53 mm) before ripping the 1 in (25.4 mm) mesh captures and 1/2 in (12.7 mm) lining clamps. Route the separate wire rebates with solid outer screw lands. Never feed short finished strips alone into a planer.
2. Prepare glazing spacers from 3/8 in (9.53 mm) rough thickness and rear beads from 1/4 in (6.35 mm) stock. Retain specified widths; plane the spacer to the received pane, two uncompressed pads and cured films, 0.351 in (8.92 mm) bare reference. Use qualified milling if guarded equipment cannot support the work.

Check before continuing: Each current stock allocation preserves grain, rough allowances and saw-cut waste.

Exact workshop reference · Show this stage in 3D

11. Laminate the continuous front frame — 1

Parts: F0L, F0M, F0R, F0BL, F0BR, F0TL, F0TR, F1L, F1M, F1R, F1B, F1T, F2L, F2M, F2R, F2BL, F2BR, F2TL, F2TR, F3L, F3M, F3R, F3B, F3T

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Glue is supplementary; every mechanical stitch is required. Keep fresh layers flat and unstressed.

1. Dry-lay layer 1 with all three uprights running full height; fit its split top and bottom rails between them. In layer 2, both rails run full width and the uprights fit between them. Repeat these arrangements for layers 3 and 4.
2. Dry-fit the four-layer frame to 70 19/32 in (1793.08 mm) wide × 46 19/32 in (1183.48 mm) high and 3 in (76.2 mm) deep. The centre upright is 3 1/2 in (88.9 mm) wide, centred at X = 36 in (914.4 mm). Each bay is 30 3/64 in (763.19 mm) wide at reference; compare both diagonals and use matched gauges at the top and bottom.

Check before continuing: All four fixed-frame layers dry-fit square with the center upright and permanent kick rail correctly aligned.

Exact workshop reference · Show this stage in 3D

12. Laminate the continuous front frame — 2

Parts: F0L, F0M, F0R, F0BL, F0BR, F0TL, F0TR, F1L, F1M, F1R, F1B, F1T, F2L, F2M, F2R, F2BL, F2BR, F2TL, F2TR, F3L, F3M, F3R, F3B, F3T

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Glue is supplementary; every mechanical stitch is required. Keep fresh layers flat and unstressed.

1. Fit one layer at a time. Transfer its scheduled rear-entry stitch holes, clearance-drill the new layer and pilot into the preceding one. Spread Titebond III on the mating bare faces, clamp flat with straight clamping pads and fit every #8 × 1 1/4 in (31.75 mm) stitch screw before the next layer covers it. Adjacent layers use offset stations; every seam is bridged. Glue is supplementary, not a claimed structural adhesive. Glue only the layer being fitted: the published open time is 8–10 minutes at 70°F (21°C) and 50% relative humidity. Prepare all clamps and holes first; complete one interface before starting another.
2. Wipe squeeze-out and keep the frame flat and unstressed for at least 24 hours, longer if the received glue label or conditions require. Do not glue the removable retainers, roof or shell panels to this assembly.

Check before continuing: The full frame is 3 in (76.2 mm) deep, square and flat, with a fixed centre vertical divider and bottom kick rail.

Required wait: Glue: at least 24 hours unstressed; follow the received label

Exact workshop reference · Show this stage in 3D

13. Laminate both unglazed door frames — 1

Parts: DL0L, DL0R, DL0B, DL0T, DL1L, DL1R, DL1B, DL1T, DR0L, DR0R, DR0B, DR0T, DR1L, DR1R, DR1B, DR1T

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Prepare matching oversized layers for each door dry fit. After lamination and full cure, refit only the outer perimeter to 29 45/64 in (754.46 mm) wide × 22 19/32 in (573.88 mm) high. Preserve its original sight opening and rear glazing datums. Bare gaps: 3/16 in (4.76 mm) at hinge, top and bottom; 5/32 in (3.97 mm) at latch. The two mirrored leaves remain separately labeled.
2. In the front layer, uprights run full height and rails fit between them. In the rear layer, rails run full width and short uprights fit between them. Dry-fit and compare diagonals before applying glue.

Check before continuing: Both door-layer sets dry-fit flat and square with staggered joints and unchanged glazing datums.

Exact workshop reference · Show this stage in 3D

14. Laminate both unglazed door frames — 2

Parts: DL0L, DL0R, DL0B, DL0T, DL1L, DL1R, DL1B, DL1T, DR0L, DR0R, DR0B, DR0T, DR1L, DR1R, DR1B, DR1T

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Clearance-drill the rear layer at its eight scheduled stitch positions and pilot into the front layer. Apply Titebond III, clamp flat and fit all eight #8 × 1 1/4 in (31.75 mm) rear-entry screws per leaf. Keep the sight opening and outer edges square. Do not attach glazing yet.
2. Leave each leaf flat and unstressed for at least 24 hours. Mark left and right without relying on the purchased hinge’s hand name.

Check before continuing: Each door is a flat, square, 1 1/2 in (38.1 mm) thick laminated frame, ready for the unglazed fitting trial.

Required wait: Glue: at least 24 hours unstressed

Exact workshop reference · Show this stage in 3D

15. Laminate the two removable retaining panels — 1

Parts: RBL1, RBL2, RBL3, RBR1, RBR2, RBR3

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Keep retainer laminations distinct from the fixed frame. Do not glue the service joint.

1. Match RBL1–RBL3 for the left panel and RBR1–RBR3 for the right. Dry-stack each set face to face, flush at every edge, and check it against the corresponding bay. Refit each panel with 5/32 in (3.97 mm) bare side gaps. Its underside bears directly on the sealed fixed kick rail; no veneer beneath it or against receiver contact faces.
2. Transfer the rear-entry stitch grid while each stack is clamped. Drill #8 clearance through its rear and middle layers, then stopped pilots into the front layer. Apply Titebond III, clamp with straight clamping pads and install the scheduled #8 × 2 in (50.8 mm) screws from the rear. Their tips retain about 7/64 in (2.78 mm) front cover in the reference stack; recalculate for received thickness.

Check before continuing: Both three-layer retainer sets fit, and stitch pilots retain the required front cover.

Exact workshop reference · Show this stage in 3D

16. Laminate the two removable retaining panels — 2

Parts: RBL1, RBL2, RBL3, RBR1, RBR2, RBR3

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Keep retainer laminations distinct from the fixed frame. Do not glue the service joint.

1. Keep the two panels separate from each other and the fixed frame. No glue joins them to the receiver wood supports or bottom rail; their three internal layers are the only glued interfaces.
2. Clean squeeze-out, label each inside face and allow at least 24 hours unstressed cure before drilling. Reject an incomplete bond rather than hiding it under finish or the liner.

Check before continuing: Each three-layer panel remains flat and removable; its total thickness matches three layers of the actual plywood.

Required wait: Glue: at least 24 hours unstressed

Exact workshop reference · Show this stage in 3D

17. Trial the hardware and glazing — 1

Parts: HL1F, HL1M, HR1F, HR1M, BTLL1, GL, GR, SPLB, SPRB, BELB, BERB

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Unresolved hardware/material holds stop the dependent operation.

1. Trial both hinge hands with matching wood and the scheduled gaps. Put equal, fully cured accepted veneer coupons beneath the two leaves of each hinge, moving the complete axis forward by the measured stack (0.0305 in (0.77 mm) reference). Prove full flat bearing, bond/compression stability, head seating and buried #6 × 1 1/4 in (31.75 mm) tips. Do not machine proprietary holes without maker approval.
2. Check the fixed pin half remains below the removable socket and points upward. Prove an outward 100° swing and a 2 in (50.8 mm) lift after opening at least 90°. Measure actual pin engagement and removal travel; the drawing’s about 1 3/4 in (44.45 mm) projection is a reference.

Check before continuing: Both handed hinge trials prove bearing, head seating, supported swing and lift-off access.

Exact workshop reference · Show this stage in 3D

18. Trial the hardware and glazing — 2

Parts: HL1F, HL1M, HR1F, HR1M, BTLL1, GL, GR, SPLB, SPRB, BELB, BERB

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Unresolved hardware/material holds stop the dependent operation.

1. Trial the glazing with actual acrylic, two separate dry 1/16 in (1.59 mm) face pads and cured wood films. Fit spacer from 3/8 in (9.53 mm) rough stock to 0.351 in (8.92 mm) bare reference or the measured stack. The bead must bear on spacer wood with light pad contact, leaving the pane free to move.
2. Trial a complete flush connection through three actual plywood offcuts and a 1 1/2 in (38.1 mm) square receiver. Use Bolt Depot 24910 316 stainless 1/4-20 × 3 1/2 in (88.9 mm) socket flat head, 16019 washer and 16008 nylon locknut. Length includes the head. Verify 82° seat, 5/32 in (3.97 mm) hex drive, washer at most 1/16 in (1.59 mm) and actual nut height before drilling real parts.

Check before continuing: All three mockups fit the supplied hardware; no irreversible full-size hole depends on an assumed product profile.

Exact workshop reference · Show this stage in 3D

19. Attach the bottom wood supports — 1

Parts: P01, CLB, CRB, CB

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place P01 flat on a sacrificial board. Locate CLB and CRB one plywood thickness from the side edges, starting 3 in (76.2 mm) behind the front for the laminated frame. Fit CB between them at the rear-panel position.
2. Transfer the hole stations listed for the bottom wood supports. Drill 11/64 in (4.37 mm) clearance through P01 only and stopped 7/64 in (2.78 mm) pilot holes into the solid pine, adjusting the pilot after an offcut trial.

Check before continuing: Floor-support positions and scheduled clearance/pilot stations match the named parts.

Exact workshop reference · Show this stage in 3D

20. Attach the bottom wood supports — 2

Parts: P01, CLB, CRB, CB

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply Titebond III to these three floor-wood support interfaces, clamp and drive #8 × 1 1/4 in (31.75 mm) screws from below. Seat heads flush with the underside so no head interrupts continuous support.
2. Check the front-frame and back-panel recesses, wipe squeeze-out and leave the assembly flat and unstressed through the glue cure.

Check before continuing: The floor sits entirely flat, with square wood supports and an unobstructed 3 in (76.2 mm) front-frame recess.

Required wait: At least 24 hours unstressed for glued wood supports

Exact workshop reference · Show this stage in 3D

21. Fit both side walls and their supports — 1

Parts: P03L, P03R, CLU, CRU, CLT, CRT

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Clamp each rear upright between its lower and upper wood supports. Upper wood supports start 3 in (76.2 mm) behind the front and stop at the inner face of the back panel.
2. With a helper, stand each wall on the floor, flush at the outer side and front edges. Clamp the wall to its bottom wood support; do not leave it standing unsupported.

Check before continuing: Both tall walls are square, supported and temporarily braced before further fastening.

Exact workshop reference · Show this stage in 3D

22. Fit both side walls and their supports — 2

Parts: P03L, P03R, CLU, CRU, CLT, CRT

Tools / setup: Measuring tape, square, pencil and the tools named below

1. At the listed stations, clearance-drill through the plywood and pilot into the named pine receiver. Offset the future back screws from the side screws using the schedule; do not intersect their shafts.
2. Install #8 × 1 1/4 in (31.75 mm) screws and finish tightening by hand. Keep the wall joints dry during the trial so they can be disassembled for finish.

Check before continuing: Both walls are parallel and stable; all tips retain at least 1/16 in (1.59 mm) wood cover.

Exact workshop reference · Show this stage in 3D

23. Close and square the back — 1

Parts: P04, CT

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit P04 between the sides, resting on the floor and flush with their rear edges. Clamp it against CB, CT and both rear uprights.
2. Compare front and rear diagonals; make each pair equal within 1/16 in (1.59 mm). Correct an uneven support rather than forcing a twisted shell into position with screws.

Check before continuing: Front and rear diagonal pairs agree before final tightening of the back.

Exact workshop reference · Show this stage in 3D

24. Close and square the back — 2

Parts: P04, CT

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Transfer the listed stations through the back and into the receivers. Clearance-drill the plywood and use stopped pine pilots; the offset side/back stations keep screw shafts apart.
2. Fit #8 × 1 1/4 in (31.75 mm) screws, then remove clamp pressure and recheck the diagonals and continuous floor bearing.

Check before continuing: The square shell stands without relying on clamps; no back screw meets a side screw.

Exact workshop reference · Show this stage in 3D

25. Add the two intermediate rear uprights — 1

Parts: CM1, CM2

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place CM1 and CM2 inside the back with their centres 24 in (609.6 mm) and 48 in (1219.2 mm) from the left outside face. Their ends fit between the lower and upper rear wood supports.
2. Clamp CM1 and CM2 straight against P04. Transfer their listed hole stations from outside, keeping the scheduled offsets from corner and horizontal-support screws.

Check before continuing: CM1 and CM2 are straight and clamped at their own positions, clear of adjacent screw routes.

Exact workshop reference · Show this stage in 3D

26. Add the two intermediate rear uprights — 2

Parts: CM1, CM2

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Drill clearance through P04 and stopped pilots into the uprights. Fasten with #8 × 1 1/4 in (31.75 mm) screws; keep the wood beneath the future membrane free from points, splinters and proud heads.
2. Check each upright bears at both ends and the back remains flat. These members brace the panel; they do not turn the floor into an unsupported span.

Check before continuing: Four rear uprights are in place, with continuous full-floor support still required.

Exact workshop reference · Show this stage in 3D

27. Install the fixed laminated front frame — 1

Parts: F0L, F0M, F0R, F0BL, F0BR, F0TL, F0TR, F1L, F1M, F1R, F1B, F1T, F2L, F2M, F2R, F2BL, F2BR, F2TL, F2TR, F3L, F3M, F3R, F3B, F3T

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With a helper, place the cured four-layer frame in its 3 in (76.2 mm) front recess, resting on P01. Keep its outer front face flush with the side-panel fronts; centre the fixed vertical divider.
2. Clamp the frame and check both bay widths, both diagonals and the top bearing surface. The sides overlap the jamb ends; there is no glue bond between the frame and shell during this trial.

Check before continuing: The cured fixed front sits square and flush with its measured bays and top bearing plane.

Exact workshop reference · Show this stage in 3D

28. Install the fixed laminated front frame — 2

Parts: F0L, F0M, F0R, F0BL, F0BR, F0TL, F0TR, F1L, F1M, F1R, F1B, F1T, F2L, F2M, F2R, F2BL, F2BR, F2TL, F2TR, F3L, F3M, F3R, F3B, F3T

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Transfer the side stations through P03L/P03R into the full jambs. Use #8 × 2 in (50.8 mm) screws, with clearance through plywood and stopped pilots into pine. Use the scheduled alternating depth lines.
2. While the empty assembly is safely supported, drill the floor stations from below and fasten into the bottom rail with #8 × 2 in (50.8 mm) screws. Their depth lines differ from the side screws. Return the shell to continuous support and leave the fixed frame installed for the remaining trial.

Check before continuing: The entire front frame is supported, square and attached; the centre vertical divider and kick rail are permanent.

Exact workshop reference · Show this stage in 3D

29. Fit the four retainer receiver wood supports — 1

Parts: RCLL, RCLR, RCRL, RCRR

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Set RCLL, RCLR, RCRL and RCRR behind the two panel bays, resting on the bottom rail. Their front faces sit directly behind the three plywood layers of the retaining panels; their sides touch the adjoining frame uprights. Receiver fronts begin 2 7/64 in (53.58 mm) behind FRONT at the reference gauge. Keep these hidden contacts flat, sealed and unveneered.
2. Transfer all four sideways screw stations per receiver. Drill #8 clearance through the receiver only, then a stopped 7/64 in (2.78 mm) trial pilot into the adjoining laminated upright.

Check before continuing: All four receivers bear on the kick rail and their screw and bolt routes remain accessible.

Exact workshop reference · Show this stage in 3D

30. Fit the four retainer receiver wood supports — 2

Parts: RCLL, RCLR, RCRL, RCRR

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Drive the sixteen #8 × 3 in (76.2 mm) screws sideways into the frame. Each passes through 1 1/2 in (38.1 mm) of receiver and engages about 1 1/2 in (38.1 mm) of frame; do not substitute the shorter shell screws.
2. Keep these screw heights distinct from the three future bolt heights. Check the receivers are straight, immobile and free of sharp edges before placing either panel.

Check before continuing: Each receiver is fixed with four scheduled screws, and every bolt route remains clear.

Exact workshop reference · Show this stage in 3D

31. Fit both panels with flush exterior fasteners — 1

Parts: RBL1, RBL2, RBL3, BTLL1, BTLL2, BTLL3, BTLR1, BTLR2, BTLR3, RBR1, RBR2, RBR3, BTRL1, BTRL2, BTRL3, BTRR1, BTRR2, BTRR3

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Never remove any connection when the bed or any water remains. Keep recess depth and washer bearing as specified.

1. Set both cured panels on the kick rail, front flush and tops 20 in (508 mm) above the finished-floor mark, with 5/32 in (3.97 mm) bare gaps on each side. Clamp flat against the four receivers. Mark X = 4 61/64 in (125.81 mm), 33 1/2 in (850.9 mm), 38 1/2 in (977.9 mm) and 67 3/64 in (1702.99 mm) from the left outside datum; at each X, use Z = 6 21/64 in (160.73 mm), 11 53/64 in (300.43 mm) and 17 53/64 in (452.83 mm) from the floor underside. These heights are 5 1/2 in (139.7 mm), 11 in (279.4 mm) and 17 in (431.8 mm) above the reference finished floor.
2. With each loose receiver squarely clamped, make three stopped 1 in (25.4 mm)-diameter flat-bottom recesses from the rear, 5/8 in (15.88 mm) deep. Leave 7/8 in (22.23 mm) receiver thickness at each washer seat. Reassemble and clamp the stack; drill backed 9/32 in (7.14 mm) through bores at the matched centres. Never hold loose stock by hand under the bit.

Check before continuing: The matched recesses and through bores are square; all four receivers retain the scheduled bearing wood.

Exact workshop reference · Show this stage in 3D

32. Fit both panels with flush exterior fasteners — 2

Parts: RBL1, RBL2, RBL3, BTLL1, BTLL2, BTLL3, BTLR1, BTLR2, BTLR3, RBR1, RBR2, RBR3, BTRL1, BTRL2, BTRL3, BTRR1, BTRR2, BTRR3

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Never remove any connection when the bed or any water remains. Keep recess depth and washer bearing as specified.

1. Countersink only the front plywood for the actual 82° head, flush to bare wood. Preserve a 0.55 in (13.97 mm) veneer service opening at each drive. Insert the twelve 3 1/2 in (88.9 mm) machine screws from the front; fit one washer and nylon nut inside each rear recess. Trial the actual 7/16 in (11.11 mm) socket, outside diameter at most 7/8 in (22.23 mm), and a 5/32 in (3.97 mm) hex driver before lining.
2. Hand-tighten evenly without crushing wood or forcing seized stainless threads. Require two complete threads beyond nylon and at least 1/16 in (1.59 mm) screw-tip cover beneath the receiver rear face. Do not deepen recesses, omit washers or shorten wrong screws. Withdraw screws outward for removal; all twelve complete sets stay installed whenever contents or water remain.

Check before continuing: All twelve flush heads are accessible; complete recessed nut stacks have two exposed threads and covered rear tips.

Exact workshop reference · Show this stage in 3D

33. Fit the unglazed doors to their actual bays — 1

Parts: DL0L, DL0R, DL0B, DL0T, DL1L, DL1R, DL1B, DL1T, DR0L, DR0R, DR0B, DR0T, DR1L, DR1R, DR1B, DR1T

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit each cured leaf flush in its own marked bay. Use 3/16 in (4.76 mm) bare hinge/top/bottom gaps and 5/32 in (3.97 mm) bare latch gap. Two 0.0305 in (0.77 mm) opposing skins leave 0.1265 in (3.21 mm) and 0.0953 in (2.42 mm); two maximum 0.046 in (1.17 mm) skins leave 0.0955 in (2.43 mm) and 0.0643 in (1.63 mm). Record actual cured gaps and recalculate for changed layers.
2. Correct unequal diagonals before trimming. Back-bevel only each latch edge 6° away from the centre divider, retaining its front-edge position. This means the rear edge is narrower for swing clearance. Mirror the bevel on the right leaf and preserve all rear glazing datums.

Check before continuing: The reference and actual finished gaps are recorded; the viewing opening and rear pocket remain unchanged.

Exact workshop reference · Show this stage in 3D

34. Fit the unglazed doors to their actual bays — 2

Parts: DL0L, DL0R, DL0B, DL0T, DL1L, DL1R, DL1B, DL1T, DR0L, DR0R, DR0B, DR0T, DR1L, DR1R, DR1B, DR1T

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check the rear glazing spacers and beads against the door’s wider uprights. Their wood must remain outside the pane pocket; no bead screw may pass through a pane edge or its expansion gap.
2. Mark each door and bay as a pair. Remove temporary spacers only when the hinges and a helper support the leaf. Acrylic remains out during this fitting stage.

Check before continuing: The reference and actual finished gaps are recorded; the viewing opening and rear pocket remain unchanged.

Exact workshop reference · Show this stage in 3D

35. Route the side-capture wire pockets

Parts: VLB, VLT, VLF, VLA, ML

Tools / setup: Supported router jig, depth stop, actual wire and cured film sample

Before you begin: Qualify the actual cut wire edges and coating before assembly.

1. On the broad 3/8 in (9.53 mm) capture stock, lay out the pocket and separate outside bearing land. Route the wall-facing rebate with a supported guide and depth stop; do not hand-hold a loose narrow piece. Reference depth is 0.088 in (2.24 mm) for 0.082 in (2.08 mm) crossing wire plus 0.006 in (0.15 mm) cured films.
2. Trial the actual wire and film. Each widened 1 in (25.4 mm) capture must lie flat on its solid 0.494 in (12.55 mm) reference outer land, enclosing every cut wire end. The rebate cannot exceed 1/8 in (3.18 mm) without redesign. Drill screws through the separate land, never through wire.

Check before continuing: Capture bears flat; wire and screw paths are separate.

Exact workshop reference · Show this stage in 3D

36. Capture the two side-vent meshes — 1

Parts: VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, ML, MR

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Cut two 19 in (482.6 mm) × 5 in (127 mm) mesh blanks with protected hands and snips. Flatten the edges and remove loose wire ends; do not leave a burr pointing into the enclosure.
2. Centre each blank over its vent from outside, giving 1/2 in (12.7 mm) overlap around the opening. Set the lower and upper capture strips, then the end strips between them. Use widened 1 in (25.4 mm) captures with 0.088 in (2.24 mm) reference wall-facing wire rebates and 0.494 in (12.55 mm) solid outer bearing lands. Trial the received crossing and cured film; no veneer lies beneath capture bearing.

Check before continuing: Every cut side-wire edge stays inside its capture pocket and the solid outer lands bear on wood.

Exact workshop reference · Show this stage in 3D

37. Capture the two side-vent meshes — 2

Parts: VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, ML, MR

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use scheduled revised outer-land stations clear of wire. Clearance-drill captures, stop #6 pilots in the wall and fit #6 × 1 in (25.4 mm) screws flush with bare wood, with accessible veneer drive openings and at least 1/16 in (1.59 mm) interior tip cover.
2. Inspect the entire captured perimeter. No wire end should be reachable through the inner opening or pull free when checked by hand. A smaller containment mesh opening, if required later, needs its own retained mounting and ventilation review.

Check before continuing: Both meshes are mechanically captured and the inner wood reveals are smooth.

Exact workshop reference · Show this stage in 3D

38. Route the roof-capture wire pockets

Parts: RTLF, RTLA, RTLL, RTLR, MTL

Tools / setup: Supported router jig, depth stop and sample

1. Use the same accepted wire/cured-film sample to fit all twelve roof captures. Cut a 0.088 in (2.24 mm) reference roof-facing rebate, preserving the 0.494 in (12.55 mm) outer bearing land and at least 1/4 in (6.35 mm) wood beneath the pocket.
2. Machine with broad stock and safe supported stops before cutting narrow final lengths. Dry-seat the three complete 19 in (482.6 mm) × 29 in (736.6 mm) wire blanks and verify all four captures bear on roof wood without rocking.

Check before continuing: Entire wire perimeter is enclosed and the solid outer lands touch P02.

Exact workshop reference · Show this stage in 3D

39. Build the removable screened roof — 1

Parts: P02, CR1, CR2, MTL, RTLF, RTLA, RTLL, RTLR, MTM, RTMF, RTMA, RTML, RTMR, MTR, RTRF, RTRA, RTRL, RTRR

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Lay P02 upside down on a padded bench. Centre three 19 in (482.6 mm) × 29 in (736.6 mm) mesh blanks over the roof openings, keeping 1/2 in (12.7 mm) edge overlap.
2. Fit twelve widened captures around the three openings, with 0.088 in (2.24 mm) roof-facing rebates for the 0.082 in (2.08 mm) two-wire crossing plus 0.006 in (0.15 mm) reference films. Solid outer lands bear on P02; use scheduled #6 × 1 in (25.4 mm) outer-land screws. Do not force strips over wire or pierce the roof face.

Check before continuing: All three roof meshes and twelve captures fit flat; both solid roof webs and rib routes remain intact.

Exact workshop reference · Show this stage in 3D

40. Build the removable screened roof — 2

Parts: P02, CR1, CR2, MTL, RTLF, RTLA, RTLL, RTLR, MTM, RTMF, RTMA, RTML, RTMR, MTR, RTRF, RTRA, RTRL, RTRR

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit CR1 and CR2 beneath the two solid webs, centred at 25 in (635 mm) and 47 in (1193.8 mm) from the left. Drill from the roof top and fit #8 × 1 1/4 in (31.75 mm) screws into the ribs.
2. Check the roof fits on the fixed front frame, side upper wood supports and rear upper wood support. Transfer its attachment stations, then set it aside for finishing. Screens carry no light fixture, climbing or lifting load.

Check before continuing: Both ribs remain under solid webs; every mesh edge is captured and the roof remains removable.

Exact workshop reference · Show this stage in 3D

41. Hang both doors on true lift-off hinges — 1

Parts: HL1F, HL1M, HL2F, HL2M, HL3F, HL3M, HR1F, HR1M, HR2F, HR2M, HR3F, HR3M

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Support the leaf with a helper whenever a hinge is being fitted or released.

1. Support each leaf at its scheduled gaps using equal fully cured veneer coupons beneath fixed and moving hinge leaves. Keep original hinge join centres at Z = 24 29/64 in (621.11 mm), 32 5/16 in (820.74 mm) and 40 11/64 in (1020.37 mm) from the floor underside. These absolute positions remain after trimming; do not remeasure from new door ends. Align three axes per side.
2. Use the received hinge as the hole template. Its fixed lower pin half mounts on the jamb and its upper removable socket mounts on the door. In this guide the left jamb uses LSX-100R and the right LSX-100L, confirmed by the manufacturer’s fixed-half orientation.

Check before continuing: All three marked axes on each door align; equal accepted cured coupons reproduce the intended final mounting plane.

Exact workshop reference · Show this stage in 3D

42. Hang both doors on true lift-off hinges — 2

Parts: HL1F, HL1M, HL2F, HL2M, HL3F, HL3M, HR1F, HR1M, HR2F, HR2M, HR3F, HR3M

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Support the leaf with a helper whenever a hinge is being fitted or released.

1. Transfer all six actual holes per hinge on the accepted trial coupons. Drill stopped #6 pilots and fit #6 × 1 1/4 in (31.75 mm) screws. At final assembly replace coupons with continuous accepted cured face veneer beneath both hinge leaves; reference axis is 0.3061 in (7.77 mm) ahead of bare FRONT. Prove head seating and stable full bearing before proceeding.
2. Remove the spacers while supporting the leaf. Slowly swing to 100°, checking the jamb, centre vertical divider, retainer top and rear beads. At 90° or more, support and lift 2 in (50.8 mm) to clear the pins, then refit all three sockets together. Stop and correct misalignment or binding.

Check before continuing: All three axes on each door align; supported full swing and two-inch lift-off work without binding.

Exact workshop reference · Show this stage in 3D

43. Rehearse the empty cleaning route — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With the enclosure empty, lift off both doors and set them on padded supports. Remove the roof using a helper; do not use mesh as a handle.
2. After removing every bit of contents and water, remove lining clamps in reverse installation order and fold the empty liner/underlay clear. Support each panel, hold its front hex drives and remove recessed interior nuts/washers. Withdraw twelve screws outward, then draw panels forward. Keep the centre divider, fixed frame and kick rail attached.

Check before continuing: Supported doors, empty lining and both retainers can be removed while the permanent shell stays on its qualified support.

Exact workshop reference · Show this stage in 3D

44. Rehearse the empty cleaning route — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Each bare service bay is 30 3/64 in (763.19 mm) wide; opposing maximum skins leave 29.9549 in (760.85 mm). Fixed kick-rail height is 3 3/8 in (85.73 mm) above the finished-floor reference. Trial the actual cleaning tools and containers through both bays and around all rear posts.
2. Dry-fold liner and underlay blanks through the front corners and rear uprights. Confirm slack at every change of direction, space for the front clamps and a route to lift out the complete empty basin. Refit and tighten both retaining panels before continuing.

Check before continuing: The entire empty base can be serviced without removing the fixed frame or moving a loaded enclosure.

Exact workshop reference · Show this stage in 3D

45. Prepare and fully finish the wood — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Label and remove hardware, doors, retainers, roof, meshes and lining. Disassemble the dry-fitted shell as needed to reach all wood faces. Keep the cured glued assemblies intact and protect every screw location.
2. Ease edges, remove dust and repair damage. Keep structural receiver/bottom bearing faces sealed and flat. Do not fill intentional stopped nut recesses, service drives or pilots. Preserve future glue faces and bare hasp footprints; accepted hinge bearing faces receive continuous cured veneer.

Check before continuing: Removed parts are labeled, surfaces repaired and cleaned, and protected bearings and drives marked.

Exact workshop reference · Show this stage in 3D

46. Prepare and fully finish the wood — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply the current Varathane Triple Thick satin label to exposed wood and the supplier-approved presealed veneer substrate. Upper one-coat planning area is 523.51 sq ft (48.64 m²), including rectangular faces, veneer topcoat, trial and contingency. Buy 6 two-can packs of US quart (0.946 L) cans. Added coats or balancing layers need recalculation.
2. Allow the full seven-day cure at the manufacturer’s stated 70°F (21°C) and 50% relative humidity reference conditions, longer when the label or conditions require. Handle and recoat only at the permitted times. An odor check or surface dryness does not replace full cure.

Check before continuing: All wood, cut reveals and protected below-liner surfaces are covered and fully cured.

Required wait: Finish: seven days full cure at stated reference conditions; extend as required

Exact workshop reference · Show this stage in 3D

47. Approve and label the full exterior veneer

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Do not substitute an unapproved adhesive or balancing system.

1. Choose one species for the entire enclosure: maple, white oak or walnut. Obtain written supplier acceptance for the backing/PSA, balance of each panel, actual cured substrate, service temperature/humidity and cleaners. The preview textures are appearance references, not a delivered grain sample.
2. Use the veneer layouts to rough-cut labeled faces and edge/reveal strips with grain in their scheduled direction. The reference whole skin is 0.0305 in (0.77 mm) and the maximum coordinated skin is 0.046 in (1.17 mm). Measure actual cured samples; a thicker system requires new dimensions and motion checks.

Check before continuing: The selected whole system and actual thickness are accepted before sticking any full sheet.

Exact workshop reference · Show this stage in 3D

48. Apply the skins without bridging removable parts

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Acclimate and prepare the veneer and sealed substrate for the supplier’s written conditions. Follow its pressure tool, application sequence and full bond-development wait. Retain that required duration in the receiving record; this guide does not invent one. Start with a matching offcut sample and inspect bond and balance first.
2. Apply each scheduled exterior face, roof surface, exposed edge and reveal separately. Stop vent edge bands at bare butt joints; fit the wall skin 1/64 in (0.4 mm) outside the finished vent-frame perimeter. Stop the four kick-rail ledge skins 1/64 in (0.4 mm) before their receivers, leaving hidden bearings bare. Keep the retainer underside and receiver-contact faces bare and sealed; preserve all service seams, traced bare hasp footprints and 0.55 in (13.97 mm) retainer-drive openings. Trim with a supported straightedge and sharp tool without rounding the reference mating edge.

Check before continuing: All exposed plywood edges are covered, while joints, bearing seats and drives stay accessible.

Required wait: Supplier-specified acclimation, pressure and full bond-development wait; unresolved H03 must be closed first.

Exact workshop reference · Show this stage in 3D

49. Topcoat and fully cure the completed veneer

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply only the supplier-accepted clear finish to the completed veneer, exposed edges and reveals. Keep bare hasp seats, drives and future bond faces masked; hinge bearing faces retain the accepted continuous cured veneer. Follow the actual label temperature, humidity, recoat and handling limits.
2. Allow the Varathane full seven-day cure at 70°F (21°C) and 50% relative humidity, or longer if the label/conditions require, before renewed assembly tests. Surface dryness or lack of smell is not proof of cure. Check the sample bond, panel flatness and actual completed skin again.

Check before continuing: All finishes are fully cured and the accepted actual veneer stack remains within the coordinated allowance.

Required wait: At least seven days full finish cure at stated reference conditions; extend as required.

Exact workshop reference · Show this stage in 3D

50. Reassemble and check the cured shell — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Refit the floor, sides, back, rear uprights and fixed front frame to their labeled holes. Hand-tighten the scheduled screws, checking their seating and covered tips; replace a damaged receiver properly rather than using an arbitrary longer screw.
2. Refit all four receivers and both panels with twelve complete flush screw/washer/recessed-nut sets. Recheck two full threads, covered tails, accessible front drives, flat bearing and diagonals on the permanent support. Protect every rear recess with loose supplementary underlay before lining.

Check before continuing: The reassembled shell and all twelve retainer connections are square and accessible without crushing wood.

Exact workshop reference · Show this stage in 3D

51. Reassemble and check the cured shell — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Refit the side mesh and roof mesh assemblies. Rehang the unglazed doors and repeat full swing, removal and refitting after the finish has changed the surfaces. Do not scrape or force cured mating faces into place. Repeat with actual cured veneer, mirrored latch bevels and retainer-top gaps. Any exposed wood after adjustment needs resealing and full recure.
2. Remove both supported doors and the roof again for lining. Keep all twelve complete connections installed. Smooth and pad the stopped rear nut pockets and all hard corners; protect the membrane without creating unsupported folds.

Check before continuing: The cured shell is square and mechanically complete, with clear door motion and a smooth basin backing.

Exact workshop reference · Show this stage in 3D

52. Fit and test the continuous basin — 1

Parts: LCL, LCR, LCFJ1, LCFRL, LCFPL, LCFRM, LCFJM, LCFML, LCFPR, LCFRR, LCFJ2, LCB1, LCB2, LCB3, LCPL, LCP1, LCP2, LCPR, LINER, UNDERLAY

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Never cut, drill or staple below the upper dry clamping band. The shallow observation is not a load test.

1. Cut one 124 in (3149.6 mm) × 88 in (2235.2 mm) blank each of underlay and EPDM from the exact 120 in (3048 mm) × 144 in (3657.6 mm) stock. Orient the long cut along the stock’s 144 in (3657.6 mm) length. Dry-fold first; do not trim away a corner to make it lie flat.
2. Lay underlay, then liner, across the central floor and over the raised bottom supports. Form relaxed folds around the four front receiver wood supports, fixed front uprights and four rear uprights. Leave slack at each inside corner; no membrane should bridge a sharp edge or stretch across a unsupported pocket.

Check before continuing: Underlay covers every hard contact; the relaxed uncut basin fits all eleven post returns without unsupported folds.

Exact workshop reference · Show this stage in 3D

53. Fit and test the continuous basin — 2

Parts: LCL, LCR, LCFJ1, LCFRL, LCFPL, LCFRM, LCFJM, LCFML, LCFPR, LCFRR, LCFJ2, LCB1, LCB2, LCB3, LCPL, LCP1, LCP2, LCPR, LINER, UNDERLAY

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Never cut, drill or staple below the upper dry clamping band. The shallow observation is not a load test.

1. Dry-fit all eighteen rounded clamps with screw centers 19 3/8 in (492.13 mm) and liner top 19 3/4 in (501.65 mm) above the central lined floor, clear of the 18 in (457.2 mm) total bed. Fit LCPL/LCP1/LCP2/LCPR, then LCB1/LCB2/LCB3 and LCFJ1/LCFJM/LCFJ2, then LCL/LCR, then LCFRL/LCFPL/LCFRM/LCFML/LCFPR/LCFRR. Only the 66 scheduled screws may pierce the dry band from 19 1/8 in (485.78 mm) to 19 5/8 in (498.48 mm) above that floor. Predrill and deburr wood with the membrane removed. Refit relaxed folds and press each screw through its planned membrane station by hand before tightening. Never wind loose rubber around a drill bit. Reverse the order for removal; trim only above the final top line.
2. With all clamps and twelve retainer connections installed and the floor supported, add only 1 in (25.4 mm) of water for a 24-hour shallow seam-and-fold observation. Inspect accessible wood and the underside for leakage without moving the shell. Siphon or wet-vacuum the water, dry completely and correct any leak before filling. This shallow check is not a full-depth tank or structural test.

Check before continuing: All sixty-six clamp screws are confined to the dry band. The shallow observation is complete without visible leakage; the basin has been drained and dried.

Required wait: Shallow liner observation: 24 hours, followed by complete draining and drying.

Exact workshop reference · Show this stage in 3D

54. Cut and retain the floating acrylic panes — 1

Parts: GL, SPLL, SPLR, SPLB, SPLT, BELL, BELR, BELB, BELT, PADLLF, PADLLB, PADLRF, PADLRB, PADLBF, PADLBB, PADLTF, PADLTB, SETL0, SETL1, GR, SPRL, SPRR, SPRB, SPRT, BERL, BERR, BERB, BERT, PADRLF, PADRLB, PADRRF, PADRRB, PADRBF, PADRBB, PADRTF, PADRTB, SETR0, SETR1

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Do not drill, glue, squeeze or rigidly trap the acrylic.

1. Measure both cured pockets and the actual sheet. Each reference acrylic pane is 23 51/64 in (604.44 mm) wide × 16 23/32 in (424.66 mm) high × 0.22 in (5.59 mm) thick. Both fit one 24 in (609.6 mm) × 48 in (1219.2 mm) sheet with the specified 1/16 in (1.59 mm) rough allowance per dimension, 1/16 in (1.59 mm) perimeter trim and 1/8 in (3.18 mm) kerf. Use the layout and acrylic maker’s supported cutting method; retain masking through edge finishing.
2. Fit spacers and two lower setting pads in each frame. The pocket is 1/4 in (6.35 mm) larger than the pane in width and height; centre the pane with 1/8 in (3.18 mm) at each side and top. The lower 1/8 in (3.18 mm) gap holds the two-layer setting pads. Keep the pane free to move as temperature changes. Each lower setting location stacks two loose 1/16 in (1.59 mm) neoprene layers; no adhesive or assumed compression. Keep four locations distinct across the two doors.

Check before continuing: Actual pane and pads are measured and fitted to the cured pocket with open edge allowance.

Exact workshop reference · Show this stage in 3D

55. Cut and retain the floating acrylic panes — 2

Parts: GL, SPLL, SPLR, SPLB, SPLT, BELL, BELR, BELB, BELT, PADLLF, PADLLB, PADLRF, PADLRB, PADLBF, PADLBB, PADLTF, PADLTB, SETL0, SETL1, GR, SPRL, SPRR, SPRB, SPRT, BERL, BERR, BERB, BERT, PADRLF, PADRLB, PADRRF, PADRRB, PADRBF, PADRBB, PADRTF, PADRTB, SETR0, SETR1

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Do not drill, glue, squeeze or rigidly trap the acrylic.

1. Fit separate dry front/rear pads and rear beads. Include actual cured films when fitting 0.351 in (8.92 mm) reference bare spacers from 3/8 in (9.53 mm) rough stock. Beads seat on spacer wood. Drill bead/spacer clearance and stopped wood pilots outside the pane and its movement space.
2. Use #8 × 1 1/4 in (31.75 mm) bead screws, tightening only until beads seat on spacers. Do not squeeze the pane, drill it, glue it into the pocket or fill its movement gap. Remove masking, clean with an acrylic-compatible method and inspect for cracks, bowing and free expansion space.

Check before continuing: The pane floats with edge clearance and beads seat on wood without squeezing it.

Exact workshop reference · Show this stage in 3D

56. Cut and retain the floating acrylic panes — 3

Parts: GL, SPLL, SPLR, SPLB, SPLT, BELL, BELR, BELB, BELT, PADLLF, PADLLB, PADLRF, PADLRB, PADLBF, PADLBB, PADLTF, PADLTB, SETL0, SETL1, GR, SPRL, SPRR, SPRB, SPRT, BERL, BERR, BERB, BERT, PADRLF, PADRLB, PADRRF, PADRRB, PADRBF, PADRBB, PADRTF, PADRTB, SETR0, SETR1

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Do not drill, glue, squeeze or rigidly trap the acrylic.

1. Weigh each complete finished leaf; the independent rectangular-volume estimate is 17.76 lb (8.06 kg) per leaf including veneer and an allowance for hardware/pads/coating. Rehang with a helper and repeat swing, sag, closure and lift-off. Catalogue capacity does not rate this wooden assembly.

Check before continuing: The finished leaf is weighed and passes supported operation and removal checks.

Exact workshop reference · Show this stage in 3D

57. Fit the independent door closures — 1

Parts: L-HP-base, L-HP-pin, L-HP-flap, L-ST-base, L-ST-washer, L-ST-tab, R-HP-base, R-HP-pin, R-HP-flap, R-ST-base, R-ST-washer, R-ST-tab

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit the complete left hasp at Z = 30 5/16 in (769.94 mm) and right at Z = 34 5/16 in (871.54 mm), on the moving latch stiles and fixed centre upright F0M. Rigidly shift the left nominal assembly 5/32 in (3.97 mm) left and right assembly 5/32 in (3.97 mm) right for full plate bearing on the trimmed leaves; actual hardware and slot reach control marking.
2. Place each hinged base on its moving latch upright and the swivel-staple plate on the fixed vertical divider. Transfer the actual seven holes only after the slot, hinge and swivel operate freely. The model’s formed hardware is an illustration, not a drilling template.

Check before continuing: Both actual hasps have full bearing, accepted screw seating and free slot engagement.

Exact workshop reference · Show this stage in 3D

58. Fit the independent door closures — 2

Parts: L-HP-base, L-HP-pin, L-HP-flap, L-ST-base, L-ST-washer, L-ST-tab, R-HP-base, R-HP-pin, R-HP-flap, R-ST-base, R-ST-washer, R-ST-tab

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the fourteen #10 × 5/8 in (15.88 mm) screws: clearance through the supplied plate holes and stopped pilots into solid wood. Keep at least 1/16 in (1.59 mm) wood behind each tip and all heads seated without distorting the hardware.
2. For daily operation, align the swivel with the slot, lift the flap and open that door. To secure, close the door, place the flap over the staple and turn the swivel across the slot. Check each closure independently; optional padlocks are not part of the illustrated keyless system. Grip the solid inner edge of the latch upright ahead of the recessed pane to pull the released door open; do not pull on the glazing.

Check before continuing: Each door stays closed when pulled gently and opens only after its own hasp is released.

Exact workshop reference · Show this stage in 3D

59. Secure the removable roof — 1

Parts: P02

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Verify the basin clamps, retained glazing, mesh and closures before placing the roof. With a helper, lower it onto the fixed front frame, both side wood supports and CT without trapping the liner or a cable.
2. Transfer the roof stations: four per side, six at the front and six at the back. Drill clearance through P02 and stopped pilots into the named receiver.

Check before continuing: Scheduled roof clearance and stopped pilot stations align with their receiving supports.

Exact workshop reference · Show this stage in 3D

60. Secure the removable roof — 2

Parts: P02

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Install #8 × 1 1/4 in (31.75 mm) screws and tighten evenly by hand. Do not glue the roof. Recheck both door gaps and closure operation with the completed shell secured.
2. Keep screw heads reachable in the eventual equipment arrangement. Disconnect and independently support equipment before roof removal; never lift by the mesh.

Check before continuing: The roof cannot shift or lift unintentionally and both doors retain their correct fit.

Exact workshop reference · Show this stage in 3D

61. Complete the construction inspection — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check every screw station, all twelve retainer bolt stacks, all six hinge assemblies, both hasps, all glazing beads, all eighteen liner clamps and every mesh edge. Repair splits, burrs, stripped receivers, loose joints and exposed tips.
2. Measure actual cured gaps around both doors, panels, roof and openings. Scheduled construction clearances and 1/2 in (12.7 mm) mesh do not establish occupant or feeder containment. Recheck after roof fixing and qualified controlled loading.

Check before continuing: All fasteners, screens and actual cured gaps have been inspected and recorded.

Exact workshop reference · Show this stage in 3D

62. Complete the construction inspection — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Verify full finish cure and a dry shell beneath the shallow-tested liner. Confirm no screw, cable or drain penetrates the wet basin, and that every above-fill clamp can be accessed.
2. Rehearse supported glazed-door lift-off, refitting and secure closure. Confirm the panels’ removal sequence is understood: animals and equipment out, all contents and liquid removed, liner folded clear, then bolts and panels. Record actual finished dimensions and leaf weights. All twelve machine screws withdraw forward after the recessed nuts and washers are removed; never release a connection against loaded substrate or water.

Check before continuing: The completed construction record contains no unresolved defect; animal commissioning remains separate.

Exact workshop reference · Show this stage in 3D

63. Place and measure the complete bed — 1

Parts: SUBSTRATE

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place all permanent support and stability provisions before loading. Protect the membrane beneath hard furnishings with smooth load-spreading pads; never drag rocks or sharp tools over it.
2. Measure the entire bed from the finished central liner floor. Drainage, separators and substrate together must stay within 18 in (457.2 mm). For example, 2 in (50.8 mm) of drainage leaves at most 16 in (406.4 mm) for the other layers.

Check before continuing: The combined bed stays within its eighteen-inch limit; support and furnishings are secure.

Exact workshop reference · Show this stage in 3D

64. Place and measure the complete bed — 2

Parts: SUBSTRATE

Tools / setup: Measuring tape, square, pencil and the tools named below

1. The conservative uninterrupted floor rectangle is about 67 3/8 in (1711.33 mm) × 29 15/16 in (760.41 mm), or 14.00 sq ft (1.30 m²). Above the full bed, about 27 in (685.8 mm) remains below the lowest upper supports before fixtures and furnishings are deducted.
2. Weigh the actual wet mix and record the installed total load. Watch for support deflection, changed door gaps, joint movement and liner damage during filling. Stop and unload if anything shifts. The density calculations are planning scenarios, not permission to load an unqualified stand or floor.

Check before continuing: The complete bed stays below its line with 2 in (50.8 mm) to the retainer top and documented remaining usable space.

Exact workshop reference · Show this stage in 3D

65. Commission before animal entry — 1

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: No animal suitability or equipment support rating is assigned by this construction guide.

1. Choose the intended species, life stage and occupancy against current care requirements using the measured usable interior. This 72 in (1828.8 mm) × 36 in (914.4 mm) × 48 in (1219.2 mm) shell is a generic construction guide and assigns no species suitability.
2. Qualify every gap, latch and mesh opening for the occupant and feeders. Fit a mechanically retained finer barrier where needed, then reassess ventilation, visibility and cleaning.

Check before continuing: The intended species and life stage are recorded, with any finer containment barrier securely fitted.

Exact workshop reference · Show this stage in 3D

66. Commission before animal entry — 2

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: No animal suitability or equipment support rating is assigned by this construction guide.

1. Choose heat, light, ultraviolet and control equipment for the actual habitat. Follow each fixture’s mounting and combustible-clearance instructions, use independent supports and guards, and keep hot parts away from wood, acrylic, liner and animals. Do not place fixture weight on the mesh.
2. Plan any cable route against the real connector and strain relief before cutting. Put it above the liner, finish the cut wood and fit a retained closure. Never trap a cord in the roof joint or pierce the wet basin for a cable or improvised drain.

Check before continuing: Selected equipment has independent safe support and any cable routes are finished and secured before commissioning.

Exact workshop reference · Show this stage in 3D

67. Commission before animal entry — 3

Parts: Complete enclosure, support and received inventory, as described below

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: No animal suitability or equipment support rating is assigned by this construction guide.

1. Run the complete configured habitat unoccupied through its intended day/night and wet/dry cycles. Record temperatures, humidity, ventilation, light exposure, thermostat control, safe surfaces, secure access and cleaning practicality before animal entry.

Check before continuing: Animal entry follows a separate documented species and equipment review, after construction is complete.

Exact workshop reference · Show this stage in 3D