Build the tall wooden enclosure

1. Plan support, restraint and service space

Parts: Complete tall shell

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Do not stack, overhang the support or leave the tall shell unsupported. This is an unbuilt reference candidate.

1. Plan continuous, rigid, level support for the whole base. The bare case is 18 in (457.2 mm) wide × 18 in (457.2 mm) deep × 36 in (914.4 mm) high; the maximum veneered wood envelope is 18.092 in (459.54 mm) × 18.092 in (459.54 mm) × 36.092 in (916.74 mm), plus projecting hardware.
2. Reserve 15 in (381 mm) in front, the complete door swing sector, 4 in (101.6 mm) above each pin and clear roof lifting space. Plan the rear cable route and direct access to both restraint-bracket screws.
3. Record completed shell, contents and equipment weights. Have the supporting furniture, floor, stability and complete anti-tip load path checked for that actual load. Plan helpers and a clear transport route.

Check before continuing: Full-base support, working space and the wall connection have a documented plan.

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2. Resolve the eight receiving holds

Parts: H01–H08 and the current materials list

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: A product listing or rendered finish is not acceptance of the assembled enclosure.

1. Match exact product models and pack quantities. Resolve H01–H08 before their dependent cuts: hinges, hasp, veneer, glazing, screens/bolts, coating, support/equipment and the tall-shell restraint.
2. Choose ONE maple, white-oak or walnut veneer system. Ask its supplier to confirm the backing, pressure-sensitive adhesive (PSA), substrate/sealer, balancing, application pressure, acclimation and dwell for this indoor use.
3. Record actual products and answers. The complete cured veneer stack is reference 0.0305 in (0.77 mm), maximum 0.046 in (1.17 mm). Added balancing layers or substitutions require coordinated changes to the affected cuts, gaps and hardware.

Check before continuing: Required supplier and qualified-review answers are recorded before dependent work.

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3. Measure stock and save physical gauges

Parts: Plywood, pine, acrylic, EPDM, cloth, steel and hardware

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Nominal lumber names are not finished dimensions.

1. Measure the plywood at corners and centre; the reference is 0.72 in (18.29 mm). Save labeled offcuts as thickness gauges. Inspect all boards for twist, bow, split ends or voids at bearing and screw locations.
2. Measure actual acrylic, both plain EPDM layers, cloth crossings, metal and hardware. Keep unknown package screws separate; use the scheduled lengths after root and head-seat trials.
3. Record actual values in the fitting worksheet. Exact decimals describe the reference geometry; use actual clamped receivers and gauges for mating lengths, without rounding a tight cut to a nearby tape fraction.

Check before continuing: Products, condition and measured thicknesses are recorded.

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4. Prove screw pilots and head seats

Parts: Actual screws and matched wood/metal offcuts

Tools / setup: Drill, caliper, actual bits/countersink, stop, clamps and backing board

Before you begin: Clamp small work; never hold it by hand under a drill.

1. Clamp an actual stack over a backing board. A clearance hole passes the first part freely; a smaller pilot guides threads into the receiver. Begin #8 trials with 11/64 in (4.37 mm) clearance and a 7/64 in (2.78 mm) pine pilot, then match the received screw root.
2. Test the actual countersink angle and stop with a flush head. For #10 hasp screws, reference clearance is 13/64 in (5.16 mm) and pilot 1/8 in (3.18 mm); #4 cap screws use 1/8 in (3.18 mm) clearance and a root-matched pilot. Do not alter purchased metal countersinks.
3. Mark the intended tip and set a physical drill stop including the bit point. Preserve at least 1/16 in (1.59 mm) solid cover beyond each actual tip and the greater cover specified for hardware. Inspect both sides after a trial drive.

Check before continuing: No splitting, stripping, exposed points, crushed wood or proud heads.

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5. Trial the complete hinge mounting

Parts: 1798A21 pair; four SP spacers; full-height offcuts

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Custom spacer mounting and hinge capacity remain H01 until accepted.

1. On the dedicated matching offcuts reproduce the 3/16 in (4.76 mm) bare hinge gap, 1/32 in (0.79 mm) door setback and hinge centres 20 in (508 mm) apart. Trace the fixed leaves and make flat 1/32 in (0.79 mm) face seats only under those fixed leaves.
2. Trial equal full-leaf aluminium spacers under BOTH leaves: reference 1/8 in (3.18 mm), minimum 7/64 in (2.78 mm). Each is 3 in (76.2 mm) × 1 1/16 in (26.99 mm). Transfer the received three-hole patterns; require flat full bearing and supplier or qualified acceptance of this mounting.
3. Use twelve scheduled #8 × 1 1/4 in (31.75 mm) screws after the head/root trial. The reference wood engagement is 1.045 in (26.54 mm) and rear cover 0.17375 in (4.41 mm). Set the actual stopped pilots from the real stack, including the point; do not reuse old one-inch screws.

Check before continuing: Both leaves are coplanar, pin axes straight, heads flush and tips buried.

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6. Prove coated swing and pin removal

Parts: Accepted hinge trial and complete pins

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Finish the trial wood and veneer using the accepted system, fully cure, then refit. Require at least 1/16 in (1.59 mm) closed reveal and free movement through 100° without leaf, head, barrel or wood contact.
2. With a helper supporting the leaf at about 90°, withdraw the upper pin first. Withdraw the lower pin until its tip clears, then move it forward. Reserve 4 in (101.6 mm) along each extraction path; actual pin length must be no more than 3 7/16 in (87.31 mm) and head no more than 3/8 in (9.53 mm).
3. Refit lower pin then upper, without hammering misaligned knuckles. Correct identities, rocking seats and alignment before final work. Keep the accepted sample and measured settings.

Check before continuing: The roof-on removal path, complete swing and reinstallation are proved on actual hardware.

Required wait: Full coating cure and the supplier-confirmed veneer dwell before this fitted trial.

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7. Trial the keyless hasp on matching stiles

Parts: N305-979; seven #10 × 5/8 in (15.88 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: The approximate digital formed flap is not manufacturer CAD; actual release remains H02.

1. Reproduce the fixed stile, retained door latch edge, 3/16 in (4.76 mm) bare gap and 1/32 in (0.79 mm) setback. The narrow hinged base goes on FAR; the square swivel plate goes on DAR. Only the fixed base receives a traced 1/32 in (0.79 mm) face seat.
2. Fit the received plates with their entire backs on solid wood. The reference moving-plate outer margin is only 0.0175 in (0.44 mm); require actual full bearing and hole centres at least 1/4 in (6.35 mm) from wood edges and other shafts. Do not drill from the picture.
3. Trial all seven separate #10 × 5/8 in (15.88 mm) screws and stopped pilots, retaining at least 1/2 in (12.7 mm) rear cover. Turn the swivel to align with the slot, release the flap fully, open, then close and turn across the slot by hand. Repeat after full cure.

Check before continuing: Both plates bear fully and the actual hasp releases without pulling the leaf sideways.

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8. Trial the complete anti-tip kit and access window

Parts: Hillman 9976524 complete kit; plywood and square-pine offcuts

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Bracket dimensions and holes are not published in the current evidence. Do not invent them or enlarge the window to force a fit.

1. Bench-assemble the furniture bracket, cable eye, clevis and cotter. Make a 6 in (152.4 mm) × 1 1/4 in (31.75 mm) plywood window over continuous 1 1/2 in (38.1 mm) square pine; include the accepted veneer on the window reveals.
2. Orient the actual bracket horizontally with its entire base inside a centred 5 1/2 in (139.7 mm) × 1 in (25.4 mm) band. Keep its screw centres at least 3/8 in (9.53 mm) from the pine top/bottom. Transfer the real holes; trial the two supplied 5/8 in (15.88 mm) furniture screws with root-matched pilots stopped at 5/8 in (15.88 mm) maximum including the point.
3. Require full direct wood bearing, at least 7/8 in (22.23 mm) rear wood, straight driver access to both heads and 1/8 in (3.18 mm) cable clearance. Prove the complete bracket can enter and leave the recess. For clevis service, remove the two accessible furniture screws and bring the bracket outside.

Check before continuing: The actual kit, tools and removal fit pass before P04 is cut.

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9. Make the cured glazing test piece

Parts: Door offcut, actual pane, two EPDM layers, Q spacer and B cap

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Do not resolve a failed cushion fit by tightening harder.

1. Make a small complete sample with the same bare glue lands, coating, full cure and actual products as the final door. Start with a 5/16 in (7.94 mm) spacer and 1/4 in (6.35 mm) cap. Both plain EPDM layers are 1/16 in (1.59 mm) raw thickness; no adhesive contacts the pane.
2. Hand-seat the cap on its solid Q land. The reference 0.22 in (5.59 mm) pane leaves 0.04625 in (1.17 mm) for each cushion, a calculated 26% deflection. This does not measure pressure or prove material compatibility.
3. Require flat, quiet acrylic, even cushioning and free edges. Correct overlap, proud heads or uneven lands first. If it fails, obtain product-specific fitting advice and prove the revised stack before final spacer planing or glue. Record the accepted setting on a measuring strip.

Check before continuing: The retained cured sample seats without bow, rattle or forced screw pressure.

Required wait: Complete glue hold, finish cure and any specified conditioning before measuring.

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10. Cut and label the five plywood panels

Parts: P01, P02, P03L, P03R and P04

Tools / setup: Supported sheet saw, straight guide, clamps, square and sacrificial surface

1. Follow the FOUR 23 3/4 in (603.25 mm) × 47 3/4 in (1212.85 mm) project-panel layouts with their edge trims and 1/8 in (3.18 mm) kerfs. Finish P01 and P02 at 18 in (457.2 mm) square. Support the sheet and waste throughout every cut.
2. Side height is 36 in (914.4 mm) minus twice the actual plywood thickness; reference 34.56 in (877.82 mm). Fit P04 between the sides: width is 18 in (457.2 mm) minus twice that thickness, reference 16.56 in (420.62 mm), and height matches the sides.
3. Label FRONT, LEFT/RIGHT, inside/outside and each part ID. Compare diagonals and dry-clamped mating edges. Preserve the physical gauges and do not cut openings until the required product trials pass.

Check before continuing: Five square, matching panels form the intended bare envelope.

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11. Cut the two low side inlets

Parts: P03L and P03R

Tools / setup: Square, drill, supported jigsaw/router, guide, chisel and backing

1. On EACH side mark 6 in (152.4 mm) and 12 in (304.8 mm) from FRONT, and 5 in (127 mm) and 7 in (177.8 mm) above its lower cut edge. Join the lines for a 6 in (152.4 mm) × 2 in (50.8 mm) through-opening.
2. Clamp the panel flat with independent waste support. Drill a starter inside the waste, then use controlled jigsaw/router passes to the lines. Square routed corners without extending cuts into sound wood.
3. Smooth splinters and mirror the faces while retaining the same front/bottom datums. The panel bottom rests on the floor, so these local heights differ from the assembly floor-underside coordinates.

Check before continuing: Both openings match and remain clear of the planned supports.

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12. Cut the roof opening and backed rear recess

Parts: P02 and P04; accepted restraint sample

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. On P02 mark X at 3 in (76.2 mm) and 15 in (381 mm) from LEFT, Y at 4 in (101.6 mm) and 14 in (355.6 mm) from FRONT. Cut the resulting 12 in (304.8 mm) × 10 in (254 mm) roof opening with supported waste. Keep P01 solid.
2. After the complete anti-tip sample passes, centre the 6 in (152.4 mm) × 1 1/4 in (31.75 mm) rear window across P04. Its top is 1/8 in (3.18 mm) below the panel top and its bottom 1 3/8 in (34.93 mm) below that edge.
3. Cut only the back plywood. Continuous CBT later backs the entire recess with 1/8 in (3.18 mm) overlap above and below. Smooth the window without rounding away its bearing or arbitrarily enlarging the opening.

Check before continuing: Roof opening and rear window match their named datums; the floor stays solid.

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13. Mill long, wide pine before ripping

Parts: Seven separate pine-board layouts

Tools / setup: Thickness planer with safe support, caliper, supported saw, stops and clamps

Before you begin: Never feed short or narrow finished strips into a thickness planer.

1. Keep each board wide and long through thicknessing. Plane FRAME-PINE to 5/8 in (15.88 mm) and DOOR-PINE to 39/64 in (15.48 mm). The two-layer door rear aligns with the stops while its front is 1/32 in (0.79 mm) behind the fixed-frame front.
2. Use separate boards for the 3/4 in (19.05 mm) captures/lower stop, tested 5/16 in (7.94 mm) Q spacers, 1/4 in (6.35 mm) caps and 1/2 in (12.7 mm) upper stop. A seventh board supplies full-height hinge and veneer/cushion trials. These conservative purchases preserve safe planer feed length.
3. Follow machine minimum feed dimensions, use suitable dust control and support, then rip and crosscut labeled pieces to their own layout. Rout pockets on supported wide blanks before making short finished strips.

Check before continuing: Every blank has the required measured thickness and grain direction.

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14. Fit the ten solid square-pine supports

Parts: CLV/CRV; CLB/CLT/CRB/CRT; CBB/CBT/CFB/CFT

Tools / setup: Supported crosscut saw, square, stop setup and physical gauges

1. Use two solid 1 1/2 in (38.1 mm) square-pine sticks and the exact kerf-aware groups. Stick one: CLV, CRV, CLB, CBB. Stick two: CLT, CRB, CRT, CFB, CBT, CFT.
2. Reference rear uprights are 31.56 in (801.62 mm); side horizontals 16.03 in (407.16 mm); cross members 13.56 in (344.42 mm). Fit between real receivers using panel-thickness and square-stock offcuts. Preserve the full solid section.
3. Check square ends, label every member and test each dry fit. Do not force long supports into the shell or replace solid cleats with laminated scraps.

Check before continuing: All ten supports fit without distorting the panels.

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15. Lay out the crossed fixed-frame layers

Parts: FAL/FAR/FAB/FAT; FBL/FBR/FBB/FBT

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Dry-lay each 5/8 in (15.88 mm) layer on a flat bench. Front layer A has full-height 1 1/2 in (38.1 mm) stiles, a 4 in (101.6 mm) bottom rail and 1 1/2 in (38.1 mm) top rail between them. Rear layer B has full-width rails and stiles between.
2. Fit the perimeter to actual panels. Reference outside size is 16.56 in (420.62 mm) × 34.56 in (877.82 mm); the clear opening is 13.56 in (344.42 mm) × 29.06 in (738.12 mm). Each layer bridges the other layer’s butt seams.
3. Place actual plywood gauges beyond the bottom and left edges; their outer faces reproduce cabinet floor/side datums for the station drawing. Check both diagonals and full face contact before glue.

Check before continuing: The flat square layers have crossed seams and the intended opening.

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16. Glue and screw the frame on the bench

Parts: Fixed frame; twenty #8 × 1 in (25.4 mm) screws; Titebond III

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: The glue maker excludes structural/load-bearing use and continuous immersion.

1. Apply glue to clean bare mating wood above 47°F (8.3°C). At 70°F (21°C), 50% relative humidity, the maker gives 8–10 minutes open time and 20–25 minutes total assembly time. Clamp with straight cauls that spread pressure.
2. Use the twenty exact J079–J098 stations. From REAR, clearance-drill layer B and make stopped root-matched pilots into A; reference pilot extension into A is 7/16 in (11.11 mm) including the point. Nominal screw engagement is 3/8 in (9.53 mm) and rear cover 1/4 in (6.35 mm).
3. Drive flush without burying heads; compare diagonals and remove squeeze-out. Complete these screws on the bench before shell members block their driver paths.

Check before continuing: Twenty flush screws and full glued contact preserve the square frame.

Required wait: This build uses a 24-hour clamp/unstressed hold before machining or installation; extend for conditions and current maker instructions.

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17. Fit the revised bare door perimeter

Parts: DAL/DAR/DAB/DAT; DBL/DBR/DBB/DBT

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Dry-lay the two 39/64 in (15.48 mm) layers with full-height A stiles and full-width B rails. Fit 3/16 in (4.76 mm) BARE gaps on all four sides to allow veneer on opposing surfaces.
2. Reference bare leaf is 13.185 in (334.9 mm) wide × 28.685 in (728.6 mm) high. Preserve the original viewing opening, 9.7475 in (247.59 mm) × 26.31 in (668.27 mm), and the original latch edge. Trim only hinge, top and bottom per the revised parts.
3. Use actual opening gauges and the exact cut schedule. Do not copy rounded old overall door sizes or trim the latch edge further: the square hasp plate has a narrow bearing margin.

Check before continuing: The bare leaf fits with equal planned gaps and unchanged glazing datums.

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18. Glue and screw the door before retainers

Parts: Door layers; fourteen #8 × 1 in (25.4 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Glue clean bare mating faces and clamp flat under the fixed-frame glue conditions. Keep all seams crossed; measure both diagonals without using acrylic as a brace.
2. Use J099–J112 from REAR. On the loose leaf, subtract its revised left X 2.4075 in (61.15 mm) and bottom Z 4.9075 in (124.65 mm) from assembly coordinates to obtain local marks. Do not reuse offsets from the old door perimeter.
3. Clearance-drill rear layer B and blind-pilot A after the actual screw test. Reference engagement is 25/64 in (9.92 mm) and cover 7/32 in (5.56 mm). Fit all fourteen flush screws before Q spacers and B caps obstruct the driver.

Check before continuing: All screws land in the intended wood and the door remains flat.

Required wait: Keep clamped and unstressed for the 24-hour build hold before machining or hanging.

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19. Plane the six-degree latch back bevel

Parts: Cured unglazed leaf

Tools / setup: Block plane, padded clamps, straightedge and sliding bevel

1. Mark FRONT and REAR. Preserve the front latch arris, the corner between its front face and edge. Set a sliding bevel 6° from square, or 84° from the face.
2. Trial a laminated offcut first. Across the 1 7/32 in (30.96 mm) leaf thickness the rear edge retreats about 0.1281 in (3.25 mm). Use the angle and straightedge, not a rounded tape offset, to control the cut.
3. Clamp the whole leaf in padded jaws and plane light passes from both ends inward. Keep the hinge edge square. Recheck the opening, hasp bearing and all bare gaps before finishing.

Check before continuing: The rear latch corner clears while the front edge and viewing opening remain intact.

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20. Attach the side-panel supports

Parts: P03L/P03R; six side supports; twenty shell screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Lay each panel inner face up. Top and bottom supports begin 1 1/4 in (31.75 mm) behind FRONT and finish flush with the panel top/bottom. Fit the rear upright between them; use actual back plywood as a gauge to reserve the rear rebate.
2. Clamp every support, then transfer its centreline. Side horizontal rows use 4 in (101.6 mm), 9 in (228.6 mm) and 14 in (355.6 mm) from FRONT; rear-upright rows use assembly heights 6 in (152.4 mm), 14 in (355.6 mm), 22 in (558.8 mm) and 30 in (762 mm) above the floor-underside gauge.
3. Use J001–J020: clearance through plywood and stopped pilots into solid pine. Reference shell screws are #8 × 1 3/4 in (44.45 mm); pilot depth into pine is at most 1 1/8 in (28.58 mm) including its point after the actual trial. Seat flush.

Check before continuing: Support faces sit square, rear rebates are reserved and side inlets stay clear.

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21. Attach the continuous back supports

Parts: P04; CBB and CBT; six shell screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Use square-pine offcuts at both back-panel side edges to fit CBB/CBT between the rear uprights. Reference length is 13.56 in (344.42 mm). Align them flush with the panel bottom/top.
2. Keep CBT continuous behind the entire rear restraint window. Mark J039–J044 using the left/floor plywood gauges: lower X at 5 in (127 mm), 9 in (228.6 mm) and 13 in (330.2 mm); upper X at 3 in (76.2 mm), 5 in (127 mm) and 13 in (330.2 mm), each row 3/4 in (19.05 mm) from its panel edge.
3. Clamp, clearance-drill the panel, stopped-pilot the pine and fit six #8 × 1 3/4 in (44.45 mm) screws flush. The separate eight back-to-upright screws go in during shell assembly.

Check before continuing: Both cross members bear fully and CBT backs the whole access recess.

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22. Stand and brace the shell around the floor

Parts: P01; prepared sides/back; fixed frame; CFB/CFT

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Do not leave the tall partly fastened shell standing unsupported.

1. On continuous flat support, stand the sides on P01 with a helper carrying loose panels. Fit P04 between them, rear face flush to side rear edges. Clamp and brace; compare diagonals.
2. Fit the laminated front frame between sides with its front face flush. Fit CFB/CFT directly behind it between the side supports; keep those cross members clamped until floor and roof ties are installed.
3. Fit J021–J038: eight back-to-upright screws at heights 8 in (203.2 mm), 16 in (406.4 mm), 24 in (609.6 mm), 32 in (812.8 mm) and ten side-to-frame screws at 3 in (76.2 mm), 10 in (254 mm), 18 in (457.2 mm), 27 in (685.8 mm), 33 in (838.2 mm). The side-front row is 5/16 in (7.94 mm) behind FRONT. Use exact transferred receiver lines and stopped pilots.

Check before continuing: The shell is square, supported and braced with no forced joints.

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23. Fasten the floor on broad padded support

Parts: P01; seventeen #8 × 1 3/4 in (44.45 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Transfer the actual side and cross-cleat centre lines onto P01 before closing the shell. Use J045–J061: six side-support, four front-cross, four rear-cross and three front-frame ties.
2. With helpers, support the clamped shell on a broad padded surface to access the underside. Never balance it on one narrow edge. Keep every loose member restrained while changing orientation.
3. Clearance-drill plywood, make stopped pilots into pine and drive only to flush. Check diagonals before final seating and mark every matched position for disassembly.

Check before continuing: The floor bears continuously and all seventeen ties enter sound receivers.

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24. Dry-fit the removable roof

Parts: P02; seventeen shell screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Transfer the actual support centre lines to the matching roof. Use J062–J078 with the same row families as the floor; all holes stay outside the roof opening.
2. Fit from above while the shell stays square and fully supported. Use actual-root-matched stopped pilots and #8 × 1 3/4 in (44.45 mm) screws flush in P02. Preserve the labels and matched holes.
3. Support and remove the roof again for inside capture work. Confirm it seats freely without using screws to pull bowed stock flat.

Check before continuing: The roof seats and removes cleanly; seventeen labeled service screws remain accessible.

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25. Transfer the actual restraint bracket holes

Parts: CBT access recess; tested complete kit

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: The kit’s rating does not rate the CBT/roof/back assembly; H08 includes the full load path.

1. Centre the tested preassembled bracket on CBT inside the 5 1/2 in (139.7 mm) × 1 in (25.4 mm) band. Its backing must bear directly on solid wood; veneer is omitted only beneath the actual bearing footprint.
2. Compare every actual shaft with the scheduled back/roof screws, retaining at least 1/4 in (6.35 mm) shaft separation. Shift horizontally only within the accepted band, then repeat the complete fit trial and record its final location.
3. Use the two supplied 5/8 in (15.88 mm) furniture screws and proven stopped pilots. Repeat both straight driver approaches, cable clearance and bracket withdrawal. Remove the kit for finishing; the two 1 1/2 in (38.1 mm) wall screws are not furniture screws.

Check before continuing: Actual holes and service paths are recorded before finishing.

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26. Fit the tested spacer and cap stock

Parts: QL/QR/QB/QT; BL/BR/BB/BT

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Repeat the retained cured coupon with final materials before planing Q stock. Reference Q depth is 5/16 in (7.94 mm); side widths 3/8 in (9.53 mm) and end widths 5/16 in (7.94 mm). Caps are 1/4 in (6.35 mm) thick, sides 3/4 in (19.05 mm) wide and ends 11/16 in (17.46 mm) wide.
2. Lay pieces against the exact viewing-opening datums. Side spacers leave 1/8 in (3.18 mm) raw pane edge float; the pane bears 3/8 in (9.53 mm) on the front door and the caps overlap it 1/4 in (6.35 mm).
3. Dry-fit the end caps clear of both stops: reference bare clearance 1/16 in (1.59 mm), minimum after cure 1/32 in (0.79 mm). Label each matched part and do not force a different spacer depth without revising the coupled stack.

Check before continuing: The tested stack, opening, pane float and stop clearance agree.

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27. Glue Q spacers and drill removable caps

Parts: Q spacers, B caps; sixteen #4 × 1 in (25.4 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Glue the Q front lands to clean bare door wood, keeping glue out of the pocket. Clamp flat. After the glue hold, clamp the caps on their hard Q lands without acrylic.
2. Use J149–J164. Side rows follow Q centre lines at assembly heights 7 1/2 in (190.5 mm), 12 1/2 in (317.5 mm), 17 1/2 in (444.5 mm), 22 1/2 in (571.5 mm), 27 1/2 in (698.5 mm), 31 1/2 in (800.1 mm); end rows use X 6 in (152.4 mm) and 12 in (304.8 mm). Transfer from the revised loose-door setup datums.
3. Drill 1/8 in (3.18 mm) clearance through cap and Q only, then a received-root pilot at most 1/2 in (12.7 mm) into the door including the point. Fit #4 × 1 in (25.4 mm) heads flush; nominal door engagement is 7/16 in (11.11 mm). Remove and label caps for coating.

Check before continuing: Sixteen screws pass through wood only; caps remain removable.

Required wait: At least the 24-hour unstressed glue hold before drilling or loading the spacers.

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28. Fit lower and upper closing stops

Parts: S01 and S02; six #8 × 1 1/4 in (31.75 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Centre the 10 in (254 mm) lower S01 with its top 1/2 in (12.7 mm) above the lower rail top and its front against FBB. Centre upper S02 with its top against CFT underside and its front aligned with the frame rear.
2. Mark each stop 1 in (25.4 mm), 5 in (127 mm) and 9 in (228.6 mm) from its left end. S01 screws enter toward FRONT, 1/4 in (6.35 mm) above its lower edge. S02 screws enter UP at the centre of its 3/4 in (19.05 mm) depth.
3. Clearance-drill the stops; blind-pilot their named receivers. Fit J143–J148 while the leaf is removed. Reference engagement is 1/2 in (12.7 mm) in FBB and 3/4 in (19.05 mm) in CFT. Check the actual leaf and cap clearance against both stops.

Check before continuing: Stops support closing without touching the retainers or forcing the pane.

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29. Make the four equal hinge spacers

Parts: HSP aluminium; SP-H1/H2 fixed/moving

Tools / setup: Vise, supported metal saw/drill, backing, files and caliper

1. Cut four 3 in (76.2 mm) × 1 1/16 in (26.99 mm) full-leaf spacers from the scheduled 1 1/2 in (38.1 mm) × 36 in (914.4 mm) × 1/8 in (3.18 mm) bar using supported work and a vise. Keep the accepted thickness equal for both leaves of both hinges.
2. Transfer actual three-hole patterns from the accepted sample; drill clamped over backing with suitable metal bits. Deburr holes and all edges until each part sits flat with no sharp burr.
3. Keep at least 7/64 in (2.78 mm) measured thickness. Recheck flat bearing, accepted screw head seating and engagement; label fixed/moving and upper/lower positions.

Check before continuing: Four matched spacers reproduce the accepted hardware trial.

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30. Hang the bare leaf with revised gaps

Parts: Two hinges, four spacers, twelve #8 × 1 1/4 in (31.75 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Any planing must preserve glazing bearing, screw-edge distances and the hasp’s narrow latch-edge support.

1. Lay the supported shell on its back. Block the door against both stops with 3/16 in (4.76 mm) bare gaps all round. Reference hinge centres are 9 5/16 in (236.54 mm) and 29 5/16 in (744.54 mm) above FLOOR UNDERSIDE.
2. Transfer the proven fixed-leaf seats and real hole patterns. Keep all shafts at least 1/4 in (6.35 mm) from existing shafts. If actual patterns conflict, move both hinges vertically together no more than 1/4 in (6.35 mm), retain their 20 in (508 mm) spacing and repeat the entire trial before drilling.
3. Fit equal spacers, twelve scheduled screws and aligned pins. Remove shims; test supported swing, stop contact and roof-on pin service. Do not bend hinges or enlarge metal holes to correct fit.

Check before continuing: The unglazed leaf moves freely and all plates have full bearing.

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31. Cut the three hardware-cloth blanks

Parts: HC23610 half-inch 19-gauge cloth

Tools / setup: Suitable snips, clamped support, edge file and caliper

1. Cut two side blanks 7 1/2 in (190.5 mm) × 3 1/2 in (88.9 mm) and one roof blank 13 in (330.2 mm) × 11 1/2 in (292.1 mm). Keep the reference half-inch clear openings and intact crossings; measure actual wire and pitch.
2. Control each cut edge, collect every clipping and file sharp ends. Wear appropriate hand protection while handling cut mesh, keeping it away from rotating tools.
3. Actual crossings must be no more than 3/32 in (2.38 mm) and fit below the cured 1/8 in (3.18 mm) capture pocket. The listed aperture is not approval for any particular animal or feeder.

Check before continuing: All three labeled blanks are flat and their cut edges will be fully captured.

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32. Recess both side capture frames

Parts: VL/VR battens and two side screens

Tools / setup: Supported router, guides, depth gauge, clamps and backing

1. Use 1 in (25.4 mm) wide × 3/4 in (19.05 mm) thick battens. Centre each screen over its 6 in (152.4 mm) × 2 in (50.8 mm) inlet with 3/4 in (19.05 mm) overlap. Batten outer perimeter is 8 in (203.2 mm) × 4 in (101.6 mm) and extends 1/4 in (6.35 mm) beyond the mesh cuts.
2. On supported wide blanks rout the panel-facing pocket 1/8 in (3.18 mm) deep over the mesh footprint plus 1/8 in (3.18 mm) around it. Preserve a continuous 1/8 in (3.18 mm) outer wood land, including corner joints, before final small-part cuts.
3. Dry-clamp the actual screen beneath the battens. Wood lands must sit flat with no wire beneath them. Confirm the measured crossing plus cured film fits without lifting a land.

Check before continuing: Every edge and corner has continuous solid bearing around the captured wire.

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33. Transfer open-cell side screw paths

Parts: Sixteen #8 × 1 1/4 in (31.75 mm) retention screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. On each actual screen centre every scheduled screw in a clear cell. Use the revised J113–J128 reference positions and check the real pitch before transfer. Do not drill a wire or clip it locally to make a screw fit.
2. With the side panel supported inner-face-up, remove the mesh before drilling. Clearance-drill battens and make root-tested plywood pilots stopped at no more than 9/16 in (14.29 mm) including the point.
3. Refit the screen and eight screws per side, flush without crushing. Nominal plywood engagement is 1/2 in (12.7 mm). Inspect every land/corner and keep all cut wire inside the pocket.

Check before continuing: Sixteen open-cell paths and complete edge capture are verified.

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34. Recess the roof capture frame

Parts: P02; RF/RB/RL/RR; M01

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Work on the detached roof inside-face-up, retaining LEFT/FRONT labels. Centre M01 over the opening: 1/2 in (12.7 mm) overlap left/right and 3/4 in (19.05 mm) front/rear.
2. RF/RB are 13 1/2 in (342.9 mm) × 1 in (25.4 mm) × 3/4 in (19.05 mm); RL/RR are 10 in (254 mm) × 3/4 in (19.05 mm) × 3/4 in (19.05 mm). Rout their panel-facing pockets 1/8 in (3.18 mm) deep over the actual mesh footprint plus 1/8 in (3.18 mm) perimeter relief.
3. Preserve continuous 1/8 in (3.18 mm) outer lands and check cured crossing clearance. Side battens must clear the shell top supports when the roof is refitted.

Check before continuing: Roof screen and captures fit without trapped wire or interference.

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35. Cut steel strips and transfer real cell centres

Parts: LB1/LB2; 1 in (25.4 mm) × 1/8 in (3.18 mm) steel bar

Tools / setup: Vise, supported metal saw/drill, backing, files and caliper

1. Cut two 11 1/2 in (292.1 mm) lengths from the 36 in (914.4 mm) bar; deburr every edge. Their width centres remain X 4 in (101.6 mm) and 8 1/2 in (215.9 mm) from roof LEFT, with ends Y 3 1/4 in (82.55 mm) and 14 3/4 in (374.65 mm) from FRONT.
2. Clamp actual cloth and strips, then transfer FOUR clear cell centres within their supported end areas. The reference bolt coordinates are X 4.2004 in (106.69 mm) and 8.5348 in (216.78 mm); Y 3 1/2 in (88.9 mm) and 14.336 in (364.13 mm). These shifted holes follow the reference grid and are not a substitute for actual mesh transfer.
3. Remove mesh, clamp metal over backing and drill 9/32 in (7.14 mm) clearance. Deburr both faces. Transfer the actual strip footprints to RF/RB and recess them beneath the wire by the measured steel thickness; keep more than 1/2 in (12.7 mm) solid wood below.

Check before continuing: Both strips touch the mesh underside and their four holes avoid wire.

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36. Countersink the four exterior roof heads

Parts: P02 roof; four actual Bolt Depot1536 flat-head screws

Tools / setup: 82-degree countersink, stopped drill, backing board, clamps, caliper and Phillips #3 screwdriver

Before you begin: H05 requires the offcut trial; H07 requires acceptance of the changed bearing and clamp force. A render does not establish connection capacity.

1. After actual open-cell transfer, separate the roof, cloth, steel and captures. Drill the four 9/32 in (7.14 mm) clearance holes through supported plywood. Use matching scrap for a complete head-seat trial before touching P02.
2. Clamp the bare roof on a sacrificial backing board. On the OUTSIDE face only, use an 82° countersink in shallow cuts. Stop the drill and test the actual head each time until its top is flush with bare plywood. No washer goes outside.
3. Published head diameter is 0.442 in (11.23 mm) – 0.477 in (12.12 mm) and head-height envelope 0.153 in (3.89 mm); the latter leaves 0.567 in (14.4 mm) of reference 0.72 in (18.29 mm) plywood. Stop at actual seating, never use that envelope as a drilling-depth target. Reject crushed fibers, voids, splitting, an oversized cone or a head sunk below the face.
4. Keep a 1/2 in (12.7 mm) circular access opening in the later roof veneer at each head. Test the actual Phillips #3 tool through it; veneer must neither carry clamping load nor cover a service head.

Check before continuing: All four actual heads seat flush without damage, and the exterior tool reaches each one.

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37. Assemble and cover the four roof bolt sets · measure first

Parts: Four L16 flat-head screws; four L17 washers; four L18 Keps nuts; four CAPS covers

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: No torque or load rating is established. Stop if a head turns in damaged wood, the nut cannot retain the joint or a cap loosens; resolve H05/H07 before use.

1. Work with the detached roof supported on the padded bench. From OUTSIDE inward: flat head in its bare-plywood seat, plywood, open mesh cell, recessed steel, capture batten, ONE washer, Keps nut and separate closed cover. Keep all wood lands flat and wire clear.
2. Measure the actual grip, washer and complete Keps nut. Reference grip is 1.47 in (37.34 mm), washer 1/16 in (1.59 mm) and Keps height 1/4 in (6.35 mm), but the Keps height is unverified. Fitted overall screw length 1 15/16 in (49.21 mm) includes the flat head and gives reference tail 0.155 in (3.94 mm). Use the measured stack, not this reference, to set the cut.
3. Require 1/8 in (3.18 mm) – 7/32 in (5.56 mm) tail beyond the fully seated primary nut, at least two complete threads after a chamfer no larger than 1/64 in (0.4 mm), and at least 1/32 in (0.79 mm) unused depth in the measured blind cap. Verify the screw has complete threads throughout the nut and cover engagement.

Check before continuing: Record the measured grip, nut height, tail, usable thread and blind-cap clearance before cutting.

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37. Assemble and cover the four roof bolt sets · fit and secure

Parts: Four L16 flat-head screws; four L17 washers; four L18 Keps nuts; four CAPS covers

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: No torque or load rating is established. Stop if a head turns in damaged wood, the nut cannot retain the joint or a cap loosens; resolve H05/H07 before use.

1. If shortening is needed, mark and remove the screw. Hold it in a vise, cut with a suitable metal saw, file and remove every burr and chip off-assembly. Protect newly exposed steel only with a supplier-accepted corrosion treatment compatible with this use; then prove clean thread fit. Never cut over the enclosure.
2. Reassemble slowly by hand, stopping if threads bind. Hold the primary Keps nut stationary with a thin 7/16 in (11.11 mm) wrench while snugging the cover with a second wrench; keep Phillips #3 at the exterior head. The cap seats against the nut without bottoming or adding wood compression. Trial the actual wrench pair and no-larger-than-3/4 in (19.05 mm) socket with the roof detached.

Check before continuing: All lands seat without crushing; primary nuts retain the connection, caps cover every sharp end, and actual tools can remove them.

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38. Fit the roof capture screws on the bench

Parts: Fourteen #8 × 1 1/4 in (31.75 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Use J129–J142 with the detached roof inside-up. Transfer actual open cells from the revised drawing: eight screws in RF/RB and six in RL/RR, separate from the four support bolts.
2. Remove screen before drilling. Clearance-drill captures, stopped-pilot plywood at no more than 9/16 in (14.29 mm) including the point and trial actual head seating. Refit mesh and screws flush.
3. Inspect all lands, wire ends, strip bearings, bolt engagement and covers. Refit the roof with its seventeen shell screws; verify side capture clearance and free roof removal.

Check before continuing: The complete roof assembly seats without obstructed drivers or trapped mesh.

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39. Fit and operate the swivel hasp

Parts: N305-979; seven #10 × 5/8 in (15.88 mm) screws

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: A padlock is optional secondary security and is not included.

1. Block the door at the accepted gaps. Reference swivel centre is X 14.78 in (375.41 mm) from LEFT and Z 19 in (482.6 mm) above FLOOR UNDERSIDE. Transfer the actual offcut-proved hardware; never use the image as a drill template.
2. Trace the fixed FAR base and its 1/32 in (0.79 mm) face seat. Check full support of both plates and every shaft against frame, door and glazing screws before stopped pilots. Fit three fixed-base and four moving-plate screws with at least 1/2 in (12.7 mm) rear wood cover.
3. Turn the swivel, swing the flap completely clear and open through the full arc. Close without pulling sideways; turn across the slot to retain the flap. Grip sound wood when moving the leaf, never the acrylic or flap.

Check before continuing: Hand release and retention work without edge contact or plate rocking.

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40. Disassemble and prepare every wood surface

Parts: Matched shell, glued frames and Q spacers

Tools / setup: Dust-controlled sanding, vacuum, lint-free cloth and ventilation

Before you begin: Resolve H03/H06 for substrate balance, bond and floor exposure before coating.

1. After all dry fits pass, label and remove hardware, screens, caps and glazing. Keep cured glued frames/Q spacers intact; separate screwed joints so every wood face and reveal is reachable.
2. Sand clean dry wood from 120 through 220 grit, vacuum and wipe with a lint-free cloth. Keep bare metal bearing seats and removable head-access areas identified; do not sand away fitted datums.
3. Confirm the complete coating/veneer/cleaning system, including the manufacturer’s floor-use exclusion. No acceptance of abrasion, permanent wet contact, immersion or animal exposure is implied.

Check before continuing: All surfaces are clean, accessible and correctly labeled.

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41. Seal the accepted substrate and fully cure

Parts: Varathane 284473 satin; accepted substrate system

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Match received cans to manufacturer 284473 and seller 284473-7482. Stir, do not shake. Apply one uniform coat along grain with a quality synthetic brush at 60–90°F (15.6–32.2°C) and below 85% relative humidity, following the current label.
2. Coat disassembled wood faces, edges and reveals as the accepted system directs, excluding bare bond/metal seats. Reference coverage includes trial pieces, preseal, veneer topcoat and loss; buy the scheduled two-can packs and recalculate for extra coats.
3. Record last application time, temperature and humidity. If another coat is needed, follow the two-hour reference recoat and 220-grit sanding instructions. Inspect flatness and defects after full cure.

Check before continuing: The accepted substrate is sound and fully cured before PSA application.

Required wait: At least seven days after the final or repaired coat at 70°F (21°C), 50% relative humidity; extend for conditions/current instructions. Touch-dry and 48-hour light use are not full cure.

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42. Trial veneer adhesion and balanced construction

Parts: Received species, backing/PSA and cured matching offcuts

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Appearance textures do not certify adhesion, species, color or delivered grain.

1. Acclimate and prepare the veneer under supplier-confirmed conditions. Apply the full wood/backing/adhesive/sealer/topcoat system to matching samples with the required pressure and dwell.
2. Measure the complete cured addition: reference 0.0305 in (0.77 mm), maximum 0.046 in (1.17 mm). Check bond, edge lift, flatness and the supplier’s balancing requirement through conditioning and the proposed cleaner trial.
3. Repeat the finished door/hinge/hasp and glazing samples. If a backer or new coating thickness is required, revise both dimensional and purchasing schedules before final application.

Check before continuing: Supplier acceptance and actual sample results are recorded.

Required wait: Actual supplier acclimation, pressing and dwell; no invented universal wait.

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43. Cut the fifty-four separate veneer skins

Parts: One 48 in (1219.2 mm) × 120 in (3048 mm) sheet in the selected species

Tools / setup: Sharp veneer knife, straightedge, cutting board and labels

1. Follow VENEER-1 and its exact coordinate table, including the separate trial blank. Keep every skin ID, grain arrow and parent part together. Rough blanks include trimming allowance.
2. Use a sharp knife, straightedge and cutting board; make supported controlled passes. Cover the roof, underside, outer faces, plywood edges and opening reveals with separate pieces.
3. Dry-arrange neighboring grain and preserve all door, roof and maintenance seams. Do not wrap one sheet across an opening or join moving assemblies.

Check before continuing: All fifty-four skins and the trial blank are identified and fit their allocation.

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44. Apply edge and opening-reveal strips first

Parts: Scheduled edge/reveal skins

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Apply each strip to the accepted cured substrate using the supplier’s pressure tool and method. Work progressively to exclude bubbles; avoid stretching thin veneer around sharp corners.
2. Trim shallow supported passes flush to the intended boundary. Face skins overlap the ends of the edge strips. Keep the rear door gasket lands unveneered.
3. Preserve the window’s actual bare bracket-bearing seat, all hinge/hasp seats, screw-head service circles and interior washer bearing seats. Keep material away from pins, holes and moving seams.

Check before continuing: All visible raw edges are covered while bearing and service paths remain usable.

Required wait: Supplier-confirmed dwell before the next finishing or assembly step.

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45. Apply the matching exterior face skins

Parts: Roof, floor underside, sides, back, fixed frame and door

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Apply the named face pieces with physical grain direction matching the dry arrangement. The roof and front edge receive the same chosen species as the side faces; no bare plywood edge remains visible.
2. Trim each removable assembly independently. Leave the screw-access circles and actual metal seats open; veneer must not carry bolt/hinge clamping pressure or bridge service seams.
3. Check bubbles, bond, flush edge joints and flatness in raking light. The finished door must retain at least 1/16 in (1.59 mm) closed reveal around its whole perimeter; reference maximum-stack clearance is 0.0955 in (2.43 mm).

Check before continuing: The exterior is uniform, flat and independently serviceable.

Required wait: Supplier-confirmed adhesive dwell before topcoating.

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46. Topcoat and record the final full cure

Parts: Accepted veneer and compatible finish

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. After the accepted PSA dwell, apply the compatible finish along the grain. Check narrow reveals and corners for runs, and all removable seams for bridges.
2. Follow the received coating instructions, adding coat area to the allowance if another coat is needed. Sand 220 grit before a further coat and use the stated recoat timing under actual conditions.
3. Record the final or repaired coat time and conditions. Inspect bond, flatness and clearance again after full cure; odor or touch-dry checks cannot replace the required wait.

Check before continuing: The complete accepted exterior is cured, flat and free of lifted edges.

Required wait: At least seven days after the last coat at the manufacturer’s reference 70°F (21°C), 50% relative humidity, longer as required.

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47. Cut the floating acrylic to the cured pocket

Parts: G01; actual cured Q pocket

Tools / setup: Acrylic-suitable supported saw, guide, backing, deburring tool and caliper

1. Measure the cured pocket at room temperature. Reference pane is 10.4975 in (266.64 mm) × 27.06 in (687.32 mm) × 0.22 in (5.59 mm); raw edge allowance is 1/8 in (3.18 mm), calculated 0.122 in (3.1 mm) beside each coated edge. Use the actual accepted stack and opening.
2. Retain protective film during cutting. Use a supported guided saw and sharp acrylic-suitable blade with backed edges and controlled feed, following the sheet maker’s fabrication guide. Do not force score-and-snap at this thickness.
3. Deburr without losing the edge allowance, clean compatibly and dry-fit freely. No holes, adhesive or forced bending are used to secure the pane.

Check before continuing: The pane lies flat with free expansion edges and no chips or cracks.

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48. Cut both plain EPDM rings

Parts: EFL/EFR/EFB/EFT and ERL/ERR/ERB/ERT

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. From two plain 120 in (3048 mm) × 3/8 in (9.53 mm) × 1/16 in (1.59 mm) strips, cut EACH ring’s two horizontal lengths to 10.4975 in (266.64 mm). Front vertical lengths are 26.31 in (668.27 mm); rear vertical lengths are 26.56 in (674.62 mm).
2. Keep the front ring 3/8 in (9.53 mm) wide; trim the rear ring to 1/4 in (6.35 mm) wide. Total length is 147.73 in (3752.34 mm) before cutting loss. Label every piece and butt corners without overlap.
3. Place strips unbonded as in the accepted sample; no adhesive touches acrylic. Recheck actual thickness, contact compatibility and the fully cured pocket before final capture.

Check before continuing: Two correctly sized plain rings lie evenly with no overlapping corners.

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49. Reassemble the cured shell and roof

Parts: Matched shell, screens, strips and covered bolt sets

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

1. Follow the matched shell labels on full padded support. Do not bridge seams with veneer or coating; keep head access and all metal seats clear.
2. Refit the screens and steel with four flush exterior flat heads and one washer, Keps nut and fitted blind cover per connection inside. Repeat the actual head-seat, open-cell, tail, thread and cap-clearance checks from the earlier pictured roof operations.
3. Use two thin wrenches to keep the primary nut stationary while snugging the cover. Refit the supported roof with its seventeen separate shell screws and prove removal remains free.

Check before continuing: The cured shell is square, supported and serviceable.

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50. Capture the pane on a padded bench

Parts: Door, two EPDM rings, G01, Q spacers and B caps

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Do not machine a new pocket or guess a shim to force a failed actual stack.

1. Lay the door front-down on a clean padded level bench. Place the front ring, centre the pane with equal edge float, then position the rear ring and four caps.
2. Fit all sixteen #4 screws progressively and evenly by hand until caps seat on Q hard lands. Compare with the accepted coupon; no extra torque is used to pressure or bend the pane.
3. Check both faces for bow, all edges for movement space and carefully support/turn the leaf to check rattle. Remove protective film when clean assembly is ready. Correct displaced strips or raised lands before proceeding.

Check before continuing: The pane is flat, quiet and removable without destroying the leaf.

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51. Hang the glazed leaf and check final movement

Parts: Complete leaf, hinges, pins and hasp

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Digital fit does not establish hinge load capacity.

1. With helpers carrying the complete glazed leaf, align knuckles and insert the lower pin first, then upper. Never lift by acrylic or hammer a misaligned pin.
2. Release swivel/flap and check the complete 100° swing. Close against both stops; require at least 1/16 in (1.59 mm) actual perimeter reveal and 1/32 in (0.79 mm) retainer-to-stop clearance. Inspect plate bearing and every screw seat.
3. Repeat roof-on pin withdrawal, leaf removal and reinstall under controlled support. Refinish any repaired wood and complete the full cure again before use.

Check before continuing: The actual finished leaf opens, secures and removes freely.

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52. Install the supported tall-shell restraint

Parts: Proved kit, CBT holes and documented stud-wall connection

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: The kit’s advertised rating is not a rating of this enclosure or its supporting furniture.

1. Refit the preassembled furniture bracket directly to the accepted bare CBT seat with its two 5/8 in (15.88 mm) screws. Confirm firm seating, both driver paths and bracket removal with the roof on.
2. Place the whole finished base on rated continuous level support. Identify sound wood studs and concealed services before the documented wall attachment; verify actual covering thickness, screw engagement and cable reach. Drywall alone is not a receiver.
3. Use the kit’s two 1 1/2 in (38.1 mm) screws only for its documented wall connection. Seat both clevis/cotter retainers, keep cable at least 1/8 in (3.18 mm) from recess edges and preserve inspection access. Other wall types need their own documented attachment and review.

Check before continuing: Actual support, wall connection, cable route and full load path are accepted.

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53. Qualify optional equipment on the left supports

Parts: Actual fixture, bulb, controls and thermal plan

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Internal equipment is only an alternative when its maker permits that guarded mounting; this guide selects no animal or lamp.

1. For permitted screen-top placement, centre the received fixture X 6 1/4 in (158.75 mm) from roof LEFT and Y 9 in (228.6 mm) from FRONT. Require a flat rigid rim 5 1/2 in (139.7 mm) – 6 in (152.4 mm) across, overall diameter no more than 6 in (152.4 mm) and FOUR actual contacts over both steel strips through the screen.
2. Weigh fixture plus bulb: 2 lb (0.91 kg) is a proposed untested limit. The Fluker Mini Sun Dome is an example to measure, not a guaranteed fit or bulb prescription. No hanging load or lamp on unsupported mesh.
3. Keep the roof beyond X 9 1/2 in (241.3 mm) free of heat fixtures; provide shade and measure the real temperature gradient. The nominal geometric wood margin is not thermal clearance. Follow exact maker clearances and keep heat off wood, finish, acrylic and cable.

Check before continuing: Actual fixture fit, support and thermal conditions have documented acceptance.

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54. Commission the empty enclosure

Parts: Supported restrained shell and species-specific equipment plan

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: This indoor moderate-humidity shell has no immersion, species or measured ventilation approval.

1. Inspect all surfaces for sharp wire, exposed points, loose parts, cracked wood and incomplete finish. Keep dry substrate no more than 3 in (76.2 mm) above the finished floor; the reference clear inlet band above it is 2.0275 in (51.5 mm).
2. Keep furnishings and outside obstructions at least 2 in (50.8 mm) clear of both inlets and preserve the roof airflow path. Select controls, probes, lighting and furnishings for the intended species and measure conditions empty before occupancy.
3. Record prototype construction, physical stability/load/service tests, environmental measurements and qualified review separately. Resolve H01–H08 and animal/feeder containment before use. Keep wet areas in separate removable leakproof containers.

Check before continuing: Every commissioning record and receiving hold has a clear disposition.

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55. Service the roof, screens, pane and restraint

Parts: Supported empty enclosure and matched tools

Tools / setup: Tape, square, pencil, clamps and the tools named in the operation

Before you begin: Use only accepted cleaners; inspect bonds, corrosion, cushions and fasteners after moving, cleaning or equipment changes.

1. Relocate the animal to suitable temporary housing, disconnect/cool equipment and empty the enclosure. Keep the full base supported. Hold the roof while removing its seventeen screws and lift the complete assembly.
2. Remove the supported leaf by upper then lower pin. On a padded bench remove sixteen cap screws, caps and rings, then lift the floating pane. Control loose mesh before removing capture screws or roof bolt sets; protect sharp ends.
3. With the roof detached on a padded bench, hold each exterior flat head with Phillips #3. Hold the inside Keps nut still with one thin 7/16 in (11.11 mm) wrench and loosen its cover with a second wrench. Only then remove the nut and washer while supporting captures, steel and sharp mesh. Refit and repeat the measured tail, full-thread, cap-clearance and flush-head checks.
4. For restraint service, keep the shell supported, release the wall end, remove both furniture screws and bring the bracket outside before removing its clevis. Refit in the proved order and repeat all bearing, tail, gap, closure, restraint and commissioning checks after service.

Check before continuing: Maintained assemblies return to their checked condition before reuse.

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