Build the large twin-door cube enclosure

1. Plan support, handling and removal space

Parts: P01 · Continuous floor; P02 · Roof with upper exhaust

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

Before you begin: No load rating, stacking permission or species approval is supplied.

1. Start from the bare 30 in (762 mm) × 30 in (762 mm) × 30 in (762 mm) case. At the maximum allowed covering, the wood envelope is 30.092 in (764.34 mm) in each direction; hinges and hasps project farther.
2. Provide a rigid, level support under the entire finished floor. Record the actual shell, substrate, contents and equipment weights; have that complete load and stability assessed.
3. Reserve both door swing sectors, at least 14 in (355.6 mm) in front and 4 in (101.6 mm) above the upper hinge pin, plus the actual hand, tool and helper space. Rehearse a route to lift off the roof and remove each supported door.

Check before continuing: Support, helpers and all maintenance paths are recorded.

Exact workshop reference · Show this stage in 3D

2. Resolve the receiving holds

Parts: Accepted material samples and the named workshop setup

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

Before you begin: Unresolved inputs remain holds; an illustration is not product approval.

1. Read H01–H06 before buying or cutting dependent parts. Keep the actual measurements and supplier decisions on the worksheet.
2. Choose one maple, white-oak or walnut system. Confirm backing, adhesive, sealer, finish and balancing method. PSA in a product name means pressure-sensitive adhesive.
3. Use the listed material and hardware identities. A substitution requires revising the affected dimensions, holes, instructions, purchases and pictures together.

Check before continuing: Every input required by the next operation is accepted.

Exact workshop reference · Show this stage in 3D

3. Measure, mark and acclimate the stock

Parts: P01 · Continuous floor; P03 · Left side with lower inlet; F01 · Front outer stile; G1 · Door 1 OPTIX pane

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

1. Measure plywood at its corners and centre. Reference thickness is 0.703 in (17.86 mm); sheet layouts use 95.88 in (2435.35 mm) × 47.964 in (1218.29 mm) usable stock. The listing has conflicting thickness fields, so actual received sheets govern.
2. Check straight, sound 1 1/2 in (38.1 mm) square pine, 3/4 in (19.05 mm) × 7 1/4 in (184.15 mm) boards, 1/4 in (6.35 mm) lattice, 3/8 in (9.53 mm) square poplar, acrylic, mesh, steel and pads. Reject damaged or voided screw-bearing areas.
3. Acclimate as the material and veneer suppliers require. Label FRONT, INSIDE, LEFT or RIGHT, part ID and a measuring corner; save matching offcuts.

Check before continuing: Stock gauges and datums are recorded without rounding away a fit change.

Required wait: Use confirmed supplier acclimation requirements; no invented duration applies.

Exact workshop reference · Show this stage in 3D

4. Prepare supported tool setups

Parts: Accepted material samples and the named workshop setup

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

Before you begin: Never feed a short loose strip through a planer or trap the waste beside the blade.

1. Set up a flat padded bench, clamps and supported infeed/outfeed. Rehearse the largest panel and the empty case turn with help.
2. Use guards, riving knife, push aids and minimum workpiece lengths required by the actual tools. Make narrow strips from long supported stock with a suitable carrier or milling service.
3. Clamp drill and router work to a backer. Disconnect tools before changing cutters, guides or stops.

Check before continuing: Every cut has stable support and a safe hand path.

Exact workshop reference · Show this stage in 3D

5. Trial clearance holes, pilots and head seats

Parts: Accepted material samples and the named workshop setup

Tools / setup: Stopped drill, countersink, caliper, actual screws, clamps and backer

Before you begin: Do not enlarge the metal hinge or hasp countersinks to force a screw to fit.

1. A clearance hole lets the first part slide along the screw; a smaller pilot guides the thread in the receiver. Trial matching offcuts with the actual screw.
2. Reference clearances are 5/32 in (3.97 mm) for #6, 11/64 in (4.37 mm) for #8 and 13/64 in (5.16 mm) for #10 wood screws. Reference pine pilots are 3/32 in (2.38 mm), 7/64 in (2.78 mm) and 1/8 in (3.18 mm) respectively; actual root diameter and the trial govern.
3. Screen bolts use 1/4 in (6.35 mm) through holes and 82-degree flat-head seats. Trial the head in sound wood. Include the drill point in a stopped depth; leave at least 1/16 in (1.59 mm) wood behind each tip.

Check before continuing: Heads seat without splitting, crushing or exposed screw points.

Exact workshop reference · Show this stage in 3D

6. Trial the removable-pin hinges and hasps

Parts: H1-1_fixed · 1798A21 fixed leaf with knuckles; H1-1_moving · 1798A21 moving leaf with knuckles; L-HP-base · Hasp mounting leaf; L-ST-base · Swivel-staple mounting plate

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

Before you begin: Supplier or qualified acceptance and a full-size trial are still required; no hinge capacity is inferred.

1. Use matching fixed and moving frame offcuts. Trial a 3 in (76.2 mm) × 1 1/16 in (26.99 mm) × 1/8 in (3.18 mm) rigid aluminium pad under each hinge leaf, with at least 7/64 in (2.78 mm) actual pad thickness. Custom mounting acceptance remains H02.
2. Fit the exact McMaster 1798A21 hinge with its barrel forward and pin removable upward. Transfer the received holes and trial the listed #8 × 1 1/4 in (31.75 mm) flat-head screws. Both pads must bear fully on bare wood.
3. Trial the N305-979 narrow base on the trimmed latch stile and its square swivel plate on the 1 3/4 in (44.45 mm) centre post. Keep all seven holes and each plate fully supported; transfer received hardware, not the picture.

Check before continuing: Hardware seating, sound edge margins, supported swing and actual pin removal are accepted.

Exact workshop reference · Show this stage in 3D

7. Make a full-size veneer and balance trial

Parts: D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile; D1C · Door 1 half-lapped rail; D1D · Door 1 half-lapped rail

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

1. Use reserved stock to make a representative complete door frame. Apply the proposed face, edge, adhesive, sealing and finish system; a small coupon alone cannot show door balance.
2. Follow the supplier’s accepted balancing, pressure and dwell instructions. Measure the complete cured layer, including adhesive and coatings: no specified face may exceed 0.046 in (1.17 mm).
3. Record flatness, bond, finished gaps and hardware operation under the intended conditions. An added backing layer or changed stock gauge requires a coordinated revision.

Check before continuing: The cured complete-door trial stays flat and fits the accepted hardware.

Required wait: Use confirmed adhesive dwell and full coating cure; these are separate waits.

Exact workshop reference · Show this stage in 3D

8. Trial the rear spacer-and-cap glazing

Parts: D1A · Door 1 half-lapped stile; Q1L · Door 1 separate spacer L; B1L · Door 1 separate flat cap L; G1 · Door 1 OPTIX pane; E1L · Door 1 plain EPDM rear cushion L

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

Before you begin: Do not stack foam, glue the pane or tighten screws to force an incorrect stack.

1. Make a same-stock sample with the actual 3/8 in (9.53 mm) rear spacer and 1/4 in (6.35 mm) cap. The cap stops on the wood spacer; there is no routed glazing pocket in this build.
2. Finish and fully cure the sample. Fit the actual 0.22 in (5.59 mm) reference acrylic and plain 3/16 in (4.76 mm) EPDM rear strip. The modeled 0.155 in (3.94 mm) compressed strip is a fit reference, not an approved force.
3. Maintain 1/8 in (3.18 mm) pane edge clearance to the surrounding spacers. The cap must seat with light strip contact and no pane bow. Resolve actual stack, finish compatibility and contact with the suppliers.

Check before continuing: The pane is supported and unbowed; caps seat on wood.

Required wait: Complete finish cure before measuring this trial.

Exact workshop reference · Show this stage in 3D

9. Allocate the stock and rough-cut labeled blanks

Parts: P01 · Continuous floor; P02 · Roof with upper exhaust; P03 · Left side with lower inlet; P04 · Right side with lower inlet; P05 · Back

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

1. Follow this revision’s numbered stock layouts. Respect grain direction, end/edge trims and the reference 1/8 in (3.18 mm) saw kerf. Revise layouts if the measured blade or stock differs.
2. Keep installed parts separate from dedicated trial boards, veneer and foam. Retain rough fitting allowance and label every blank immediately.
3. Make supported long cuts before narrow strips. Use the exact finished dimensions and actual mating parts for final fitting; do not use a rounded tape reference as a machining setting.

Check before continuing: Every installed part and trial allowance is accounted for.

Exact workshop reference · Show this stage in 3D

10. Fit the five case panels

Parts: P01 · Continuous floor; P02 · Roof with upper exhaust; P03 · Left side with lower inlet; P04 · Right side with lower inlet; P05 · Back

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

1. Finish floor P01 and roof P02 at 30 in (762 mm) square. Reference sides P03/P04 are 30 in (762 mm) deep × 28.594 in (726.29 mm) high between the 0.703 in (17.86 mm) panels.
2. Fit back P05 between the actual sides: reference 28.594 in (726.29 mm) square. Use a story stick, a strip marked directly from the received stack, to transfer both clear dimensions.
3. Check the height and width chains close to the intended bare 30 in (762 mm) envelope. Keep joint edges square; remove splinters without rounding the measuring faces.

Check before continuing: Paired sides match and the dry case dimensions close correctly.

Exact workshop reference · Show this stage in 3D

11. Cut the roof aperture

Parts: P02 · Roof with upper exhaust

Tools / setup: Supported jigsaw/router, guide, clamps, square and backer

Before you begin: Unsupported waste can fall, tear the face or pinch the blade.

1. On a supported roof blank, mark the 22 in (558.8 mm) × 18 in (457.2 mm) opening beginning 4 in (101.6 mm) from LEFT and 6 in (152.4 mm) from FRONT.
2. Clamp the waste and panel. Use the actual tool’s supported starter and guided-cut method; keep the border intact.
3. Compare the opening diagonals and dry-fit the 24 in (609.6 mm) × 20 in (508 mm) mesh allowance and six capture pieces. Do not enlarge the opening to compensate for a crooked cut.

Check before continuing: The opening is square and agrees with the named roof datums.

Exact workshop reference · Show this stage in 3D

12. Cut the paired side ventilation openings

Parts: P03 · Left side with lower inlet; P04 · Right side with lower inlet

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

1. Mark each opening 8 in (203.2 mm) along the side × 2 in (50.8 mm) high, starting 10 in (254 mm) behind FRONT and 6 in (152.4 mm) above that side panel’s bottom edge.
2. When assembled on the reference floor, the opening bottom is 6.703 in (170.26 mm) above the floor underside. Keep panel-local and assembly datums distinct.
3. Cut on a backer with supported waste, then compare both sides. Dry-position the 10 in (254 mm) × 4 in (101.6 mm) screen and four inside battens around each opening.

Check before continuing: Both inlet openings and their capture overlap agree.

Exact workshop reference · Show this stage in 3D

13. Cut the cleats, ledgers and bearing posts

Parts: C01 · Solid rear corner cleat; C03 · Solid side bearing cleat; C07 · Solid front/back ledger; C10 · Solid front/back ledger; C11 · Solid central roof rib; C12 · Solid centre bearing post; C13 · Rear ledger bearing post; C14 · Rear ledger bearing post

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

1. Use the labeled solid-pine cut schedule. A cleat is a strip behind a joint that receives screws; a ledger is a horizontal support; posts carry the ledgers and rib.
2. Fit C01/C02 rear corners and C03–C06 side cleats to the actual case. Fit C07/C08 lower front/rear ledgers between them. Keep the top-front C09A/C09B split for centre rib C11.
3. Rough C13/C14 rear bearing posts at 24 1/4 in (615.95 mm), then fit the actual gap; the reference final length is 24.094 in (611.99 mm). C12 supports C11 from C07. Never fill a short bearing post with an unexplained gap.

Check before continuing: All intended end bearings make full contact before fastening.

Exact workshop reference · Show this stage in 3D

14. Cut and dry-stack the two front-frame layers

Parts: F01 · Front outer stile; F02 · Front outer stile; F03 · Front sill; F04 · Front header; F05 · Front centre stile; F06 · Rear centre stile

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

1. Cut F01–F12 from the reference 3/4 in (19.05 mm) board. Keep the front layer’s full-height outer stiles, sill, header and centre infill distinct from the staggered rear pieces.
2. Dry-stack both layers on a flat bench with their outside faces and door openings flush. F06 runs full height behind the centre; F07/F08 rear sills and F09/F10 rear headers end against it.
3. Check both openings, reference 11.672 in (296.47 mm) wide × 22.844 in (580.24 mm) high. Label every layer before separating it for glue.

Check before continuing: The staggered joints overlap correctly and the two openings are square.

Exact workshop reference · Show this stage in 3D

15. Glue and screw the fixed front frame

Parts: F01 · Front outer stile; F02 · Front outer stile; F03 · Front sill; F04 · Front header; F05 · Front centre stile; F06 · Rear centre stile

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

1. Glue only clean bare mating wood with Titebond III. Above the conservative 47°F (8.3°C) application minimum, spread the maker’s specified amount and assemble within the actual working time.
2. Clamp the two layers flat and square; install the 26 FRAME-LAM #8 × 1 1/4 in (31.75 mm) screws from the rear. Use the station drawing, clear first layer and stopped pilot in the front layer.
3. Remove squeeze-out while appropriate for the glue instructions, keeping later glazing, veneer and hardware seats clean. Check diagonals before leaving the assembly clamped.

Check before continuing: The frame remains flat and square with all screw tips buried.

Required wait: Titebond recommends 30–60 minutes clamping for unstressed joints; stressed joints require 24 hours. Do not stress these new joints for at least 24 hours; colder conditions may require longer.

Exact workshop reference · Show this stage in 3D

16. Cut the door-frame half-laps

Parts: D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile; D1C · Door 1 half-lapped rail; D1D · Door 1 half-lapped rail

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

Before you begin: Make supported repeated cuts with the tool’s guarded fixture; do not hold a short end at a moving cutter.

1. A half-lap removes half the thickness from two crossing pieces so they overlap flush. Start from the original door-frame blanks and transfer the actual 1 1/2 in (38.1 mm) corner width.
2. Remove the REAR half at both ends of each stile and the FRONT half at both ends of each rail. The reference depth is 3/4 in (19.05 mm); trial the actual stock so the combined joint stays 1 1/2 in (38.1 mm) thick.
3. Dry-fit both frames square with their original viewing openings retained. Label all four corners and do not reverse the shoulder faces.

Check before continuing: Each lap seats flat with no rocking or forced shoulder gap.

Exact workshop reference · Show this stage in 3D

17. Glue and fasten both door frames

Parts: D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile; D1C · Door 1 half-lapped rail; D1D · Door 1 half-lapped rail; D2A · Door 2 half-lapped stile; D2B · Door 2 half-lapped stile

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

1. Glue the bare half-lap faces, clamp each frame flat and compare diagonals. Keep the inner opening datums unchanged.
2. Install the eight DOOR-LAP #8 × 1 1/4 in (31.75 mm) screws from the rear at the scheduled corner stations, with clearance through the rear member and a stopped pilot in the front member.
3. Remove squeeze-out from the future pane contact area. Check flatness again before the glue sets.

Check before continuing: Both square frames have fully seated joints and buried tips.

Required wait: Keep the specified clamps and no-stress wait; do not machine or hang an uncured joint.

Exact workshop reference · Show this stage in 3D

18. Fit bare door gaps for the complete veneer

Parts: D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile; D1C · Door 1 half-lapped rail; D1D · Door 1 half-lapped rail; F05 · Front centre stile

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

Before you begin: Do not simply veneer the source 1/8 in (3.18 mm) gaps; they have inadequate allowance.

1. After curing, trim each original door by 1/16 in (1.59 mm) at its hinge edge and top/bottom, and 1/32 in (0.79 mm) at its latch edge. Preserve the original viewing opening and rear glazing datums.
2. Reference finished bare leaves are 11.32825 in (287.74 mm) wide × 22.469 in (570.71 mm) high. Fit to the actual frame: 3/16 in (4.76 mm) bare hinge/top/bottom gaps and 5/32 in (3.97 mm) bare latch gaps.
3. Two maximum 0.046 in (1.17 mm) opposing layers leave at least 0.06425 in (1.63 mm) at the latch. After full cure, verify every actual gap is at least 1/16 in (1.59 mm) and agrees with the species containment decision.

Check before continuing: Bare gaps allow the complete received finish without losing the viewing opening.

Exact workshop reference · Show this stage in 3D

19. Bevel the rear latch edges

Parts: D1B · Door 1 half-lapped stile; D2A · Door 2 half-lapped stile

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

1. A back bevel slopes the rear edge inward while preserving the front edge. Set a trial 6-degree bevel on the LEFT door’s right edge and the RIGHT door’s left edge.
2. Over the 1 1/2 in (38.1 mm) depth this removes about 0.158 in (4.01 mm) at the rear. Keep the front measurement, half-lap fit, hasp bearing face and pane spacer datums intact.
3. Dry-swing the supported leaves on the accepted hardware. Cover the bevel with its own veneer strip later; do not wrap a thick piece around a sharp corner.

Check before continuing: Both latch edges clear through opening without shortening the front face.

Exact workshop reference · Show this stage in 3D

20. Make the spacers, caps and acrylic panes

Parts: Q1L · Door 1 separate spacer L; Q1R · Door 1 separate spacer R; B1L · Door 1 separate flat cap L; B1R · Door 1 separate flat cap R; G1 · Door 1 OPTIX pane

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

Before you begin: Do not use an incompatible cleaner, flame finishing or an unsupported cut that cracks acrylic.

1. Cut Q1/Q2 spacer strips from 3/8 in (9.53 mm) square poplar and B1/B2 caps from 1/4 in (6.35 mm) pine lattice. Keep the left/right/top/bottom IDs; the vertical caps are 7/8 in (22.23 mm) wide and horizontal caps 3/4 in (19.05 mm) wide.
2. Each reference acrylic pane is 9.172 in (232.97 mm) wide × 20.344 in (516.74 mm) high × 0.22 in (5.59 mm) thick. Confirm the actual spacer opening and 1/8 in (3.18 mm) edge allowance before final cutting.
3. Keep the protective masking, use the acrylic maker’s supported cutting method and clean debris with compatible products. No screw hole is drilled through the pane.

Check before continuing: Both panes fit freely within their dry spacer frames.

Exact workshop reference · Show this stage in 3D

21. Drill and trial the glazing cap stations

Parts: Q1L · Door 1 separate spacer L; Q1R · Door 1 separate spacer R; B1L · Door 1 separate flat cap L; B1R · Door 1 separate flat cap R; B1B · Door 1 separate flat cap B; B1T · Door 1 separate flat cap T

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

1. Lay the door flat and supported, rear upward. Dry-fit the spacers, actual pane and accepted rear EPDM strips. Fit caps onto the wood spacer faces.
2. Transfer the 24 GLAZE #6 × 1 1/4 in (31.75 mm) stations: four on each vertical cap, two on each horizontal cap. Drill with the pane removed; countersink only the wood cap.
3. Trial fit without glue. The cap should stop on its spacer with light cushion contact, a free pane edge and no bow; then label and remove the parts for later finishing.

Check before continuing: Caps are accessible and pane removal does not depend on cutting glue.

Exact workshop reference · Show this stage in 3D

22. Cut the roof and side screen battens

Parts: R01A · Roof edge-capture batten; R01B · Roof edge-capture batten; R03 · Roof edge-capture batten; V1B · Side inlet capture batten; V1F · Side inlet capture batten

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

1. Cut six roof battens and four battens per side from 3/4 in (19.05 mm) pine. A batten is a narrow strip that traps the screen edge against the case.
2. Keep R01A/R02A beside the left steel support bay, R01B/R02B beside the right bay, and R03/R04 at the sides. Preserve the centre split around C11.
3. Dry-fit every batten against its own opening and mark the face toward the plywood. That face receives the controlled screen recess in the next operation.

Check before continuing: All capture pieces have the correct side, orientation and overlap.

Exact workshop reference · Show this stage in 3D

23. Recess the screen while retaining wood bearing

Parts: R01A · Roof edge-capture batten; R03 · Roof edge-capture batten; V1B · Side inlet capture batten; V1F · Side inlet capture batten; C11 · Solid central roof rib

Tools / setup: Stopped router or suitable milling setup, clamps, backer, caliper and actual mesh

Before you begin: Do not route away the bearing land or assume a reference pocket proves clamp strength.

1. A recess is a shallow pocket. On the plywood-facing side of each batten, relieve the screen footprint to the accepted actual crossing thickness; the reference depth is 3/32 in (2.38 mm).
2. Keep the outer 0.494 in (12.55 mm) reference land intact. That land bears on the plywood; the recessed zone contains the wire without using the screws to crush welds. The reference edge relief is 0.006 in (0.15 mm).
3. Fit C11’s own mesh relief and the roof’s steel pockets separately. Trial actual wire and plywood before repeating the routing on final battens.

Check before continuing: Wood lands seat fully and the screen remains captured with no sharp loose edges.

Exact workshop reference · Show this stage in 3D

24. Cut and contain the three screens

Parts: M01 · Roof screen blank; VM1 · Side inlet screen blank; VM2 · Side inlet screen blank

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

1. Cut roof M01 at 24 in (609.6 mm) × 20 in (508 mm) and side VM1/VM2 at 10 in (254 mm) × 4 in (101.6 mm), using the accepted received cloth and eye/hand protection.
2. Deburr and keep every cut wire edge within the batten capture footprint. Do not leave pointed ends projecting into an animal or maintenance path.
3. Register the grid to the drilling drawing. The 1/2 in (12.7 mm) centre spacing and 0.041 in (1.04 mm) wire are modeling references; measure the actual grid, welds and clear aperture before drilling.

Check before continuing: All screen edges are safely captured and the actual grid registration is recorded.

Exact workshop reference · Show this stage in 3D

25. Cut, deburr and seat the two steel strips

Parts: LB1 · Steel strip below left lamp area; LB2 · Steel strip below left lamp area; R01A · Roof edge-capture batten; R02A · Roof edge-capture batten

Tools / setup: Supported metal-cutting setup, clamped drill, file, caliper and eye protection

Before you begin: A strip and a geometric fixture fit do not establish a load or temperature rating.

1. Cut each solid steel strip 20 1/2 in (520.7 mm) long × 1 in (25.4 mm) wide × 1/8 in (3.18 mm) thick. The legacy product URL contains “Slotted”, but the selected 11653 stock is solid flat bar.
2. Clamp and drill two 1/4 in (6.35 mm) bores per strip, centred across its width and 1/2 in (12.7 mm) from each end. Deburr both faces and ends completely.
3. Fit the strip ends into the matching front/rear roof pockets. Their original absolute support centres remain 6 1/4 in (158.75 mm) and 11 3/4 in (298.45 mm) from LEFT; all four roof fixing axes must pass freely.

Check before continuing: Both strips seat fully with four matching axes and no sharp corners.

Exact workshop reference · Show this stage in 3D

26. Make eight matched hinge bearing pads

Parts: SP-H1-1-fixed · Rigid full-leaf bearing pad H1-1 fixed; SP-H1-1-moving · Rigid full-leaf bearing pad H1-1 moving

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

1. Cut eight 3 in (76.2 mm) × 1 1/16 in (26.99 mm) pads from solid nominal 1/8 in (3.18 mm) aluminium. Keep matched pairs; minimum accepted actual thickness is 7/64 in (2.78 mm).
2. Deburr all edges, check flatness and transfer the received hinge holes. Use clearance holes through the pads; do not change the hinge holes.
3. Trial full metal-to-bare-wood bearing without bridging any door gap. Keep adhesive and veneer out of these seats. Custom mounting strength and corrosion suitability require H02 acceptance.

Check before continuing: Every pad pair matches and the actual screws seat correctly.

Exact workshop reference · Show this stage in 3D

27. Dry-fit the floor, sides and lower supports

Parts: P01 · Continuous floor; P03 · Left side with lower inlet; P04 · Right side with lower inlet; C03 · Solid side bearing cleat; C04 · Solid side bearing cleat; C07 · Solid front/back ledger; C08 · Solid front/back ledger

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

1. On a padded flat bench, position the sides on the floor and place the lower side cleats and front/rear ledgers between the named members.
2. Clamp without pulling a bowed panel into alignment. Check both front datums, side height chains and the 30 in (762 mm) bare width/depth.
3. Mark the actual receiver centre lines from inside. Use the current station drawing for the exterior drill direction and retain those labels during turning.

Check before continuing: The dry lower case sits level and the cleat/ledger joints contact correctly.

Exact workshop reference · Show this stage in 3D

28. Fit the back and bearing posts

Parts: P05 · Back; C01 · Solid rear corner cleat; C02 · Solid rear corner cleat; C10 · Solid front/back ledger; C12 · Solid centre bearing post; C13 · Rear ledger bearing post; C14 · Rear ledger bearing post

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

1. Fit P05 between the sides against C01/C02. Fit the rear ledger C10 and its two fitted bearing posts C13/C14.
2. Seat centre support C12 on the front lower ledger. Position the split top-front cleats and C11 rib so its front end bears on C12 and rear end on C10.
3. Check every bearing face with a light behind the joint and compare the case diagonals. Resolve rocking, bow or a gap before drilling.

Check before continuing: The roof rib has continuous intended bearing at both ends.

Exact workshop reference · Show this stage in 3D

29. Install the cured fixed front frame

Parts: F01 · Front outer stile; F02 · Front outer stile; F03 · Front sill; F04 · Front header; F05 · Front centre stile; F06 · Rear centre stile

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

1. Clamp the cured two-layer frame into the open front with the designated outer faces flush.
2. Check both door openings and the centre support alignment. Compare front and top diagonals; use a 1/16 in (1.59 mm) maximum difference as the assembly target before drilling.
3. Rehearse removal and fitting of the roof and both doors. Do not hide a skewed case by changing one leaf or tightening an opposing screw.

Check before continuing: The front remains flat, square and aligned with the actual support members.

Exact workshop reference · Show this stage in 3D

30. Drill and screw the case in the planned order

Parts: P01 · Continuous floor; P03 · Left side with lower inlet; P04 · Right side with lower inlet; P05 · Back; F03 · Front sill

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

Before you begin: The workshop schedule distinguishes every screw length and direction; do not substitute by appearance.

1. With help, turn the EMPTY clamped assembly onto padding as needed to drill perpendicular to the actual faces. Keep panes and loose hardware off the bench.
2. Follow each named station group: side cleats/back/front, back corners/ledgers, front ledgers/centre, floor side/ledger, rear posts and rib. Clear the first member and stop the pilot in its actual receiver.
3. Install the specified #8 × 1 3/4 in (44.45 mm) or #8 × 2 1/2 in (63.5 mm) screw at that station. Check squareness as you tighten; use hand control for final seating. Preserve the removable roof.

Check before continuing: All case stations match their named receivers, with no split wood or exposed tips.

Exact workshop reference · Show this stage in 3D

31. Trial the roof as a removable assembly

Parts: P02 · Roof with upper exhaust; C05 · Solid side bearing cleat; C06 · Solid side bearing cleat; C11 · Solid central roof rib

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

1. Place the roof on the dry case and transfer the ROOF-SIDE, ROOF-RIB and ROOF-FRONT station groups from the actual supports.
2. Use the specified #8 × 1 3/4 in (44.45 mm) screws, with clear roof holes, controlled head seats and stopped receiver pilots. Check the panel is flat without forcing it down.
3. Remove the roof again for screen work. Do not glue it to the case, and keep later veneer pieces separate at this service seam.

Check before continuing: The roof can be lifted away after its accessible screws are removed.

Exact workshop reference · Show this stage in 3D

32. Transfer side screen axes through open wire cells

Parts: P03 · Left side with lower inlet; VM1 · Side inlet screen blank; V1B · Side inlet capture batten; V1T · Side inlet capture batten; V1F · Side inlet capture batten; V1R · Side inlet capture batten

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

1. With the side accessible and supported, seat the actual screen and four recessed inside battens on their intact wood lands.
2. Transfer the eight axes per side from the current drawing and actual grid. Keep every 1/4 in (6.35 mm) bore clear of wires and welds; do not cut a wire to force alignment.
3. Check a full 1 in (25.4 mm) inside washer bearing circle and room for the actual locknut, cover and driver/socket. Record any required change before repeating on the other side.

Check before continuing: All 16 side stations pass through open cells with full wood and washer bearing.

Exact workshop reference · Show this stage in 3D

33. Fit flush heads and covered inside side fixings

Parts: P03 · Left side with lower inlet; V1B · Side inlet capture batten; VM1 · Side inlet screen blank

Tools / setup: Stopped drill/countersink, caliper, thread-matching nut, metal-cutting/deburring tools, driver and two suitable wrenches

Before you begin: Do not bottom the closed cover, crush wire or use an untested torque value. Resolve H03 before dependent installation.

1. Drill through the supported stack, remove the metal/mesh and form only the outside 82-degree wood seat. Test the actual head at the bare wood plane with no outside washer.
2. Refit screen and battens. Inside, fit one washer and nylon-insert locknut per bolt, then a closed metal cover over the remaining thread.
3. Purchase 2 1/2 in (63.5 mm) bolts and fit to the actual stack. The reference final length here is 1 7/8 in (47.63 mm). Fully engage the nylon, leave at least two complete threads beyond it, and retain at least 1/32 in (0.79 mm) spare blind cover depth after deburring.

Check before continuing: Wood lands seat, outer heads are flush and all inside thread ends remain covered.

Exact workshop reference · Show this stage in 3D

34. Assemble the roof screen and steel supports

Parts: P02 · Roof with upper exhaust; M01 · Roof screen blank; R01A · Roof edge-capture batten; R01B · Roof edge-capture batten; R03 · Roof edge-capture batten; LB1 · Steel strip below left lamp area; LB2 · Steel strip below left lamp area

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

1. Support the roof upside down. Fit the two deburred steel strips in their own pockets, the screen against the roof underside and all six recessed battens.
2. Transfer all 20 axes through the actual grid and receiver lands. Four also pass through the steel bores. Confirm the central rib relief will clear when the roof returns to the case.
3. Use the same flush-outside and retained-covered-inside fixing sequence, with received-stack bolt fitting. Check the underside from every approach for wrench access and sharp ends.

Check before continuing: The roof assembly is square, independently removable and has 20 complete inside-covered connections.

Exact workshop reference · Show this stage in 3D

35. Hang and align the supported bare doors

Parts: H1-1_fixed · 1798A21 fixed leaf with knuckles; H1-1_moving · 1798A21 moving leaf with knuckles; D1A · Door 1 half-lapped stile; F01 · Front outer stile

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

1. Keep the original hinge centres at 9.328 in (236.93 mm) and 22.922 in (582.22 mm) above the floor underside. Do not remeasure the original offset from the newly trimmed door ends.
2. Clamp both leaves at the accepted bare gaps with a helper supporting their weight. Fit matched pads and received hinges to bare seats; transfer and drill the actual 24 #8 × 1 1/4 in (31.75 mm) screw stations.
3. Check that pins align, leaves seat flat and neither door drops or rubs through its supported swing. Remove a misaligned hinge and correct the fit; do not bend it by tightening.

Check before continuing: Both doors swing with sound support, positive gaps and buried screw points.

Exact workshop reference · Show this stage in 3D

36. Fit the two independent swivel hasps

Parts: F05 · Front centre stile; L-HP-base · Hasp mounting leaf; L-ST-base · Swivel-staple mounting plate; R-HP-base · Hasp mounting leaf; R-ST-base · Swivel-staple mounting plate

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

Before you begin: Padlocks are optional and not included. Do not use the drawing as a drill template or force the nominal flap through the swivel.

1. Fit the left swivel centre at 14 in (355.6 mm) and right at 20 in (508 mm) above the floor underside. Preserve the small opposite horizontal offsets shown in the drawing; the actual plate footprints and holes govern.
2. Place each narrow hinged base on its MOVING door stile and its square swivel plate on FIXED F05. Use seven received-transferred #10 × 5/8 in (15.88 mm) screws per complete hasp.
3. Trial the actual complete plates, countersinks and sound edge margins. Turn the swivel to align with the flap slot, lift the flap fully clear, then open that door. Reverse to close by hand.

Check before continuing: Each door latches independently with no key and no unsupported plate or screw.

Exact workshop reference · Show this stage in 3D

37. Rehearse pin, pane and roof removal

Parts: H1-2_pin · 1798A21 removable pin reference; G1 · Door 1 OPTIX pane; B1L · Door 1 separate flat cap L; P02 · Roof with upper exhaust

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

1. Support one open door with a helper. Remove the lower hinge pin first, then the upper, following the received hinge instructions and actual tool path. Move the freed leaf forward; never let it hang from one pin.
2. On a padded bench, support the pane, unscrew its rear caps and lift away loose rear strips and pane without prying. Keep the spacers and datums labeled.
3. Remove accessible roof screws and lift the roof clear. Check inward side-batten removal and all tool paths before finishing. Rehang by engaging the upper pin first while supported, then the lower.

Check before continuing: Every service route works without cutting glue, damaging the pane or forcing a part.

Exact workshop reference · Show this stage in 3D

38. Disassemble and prepare the finish surfaces

Parts: P01 · Continuous floor; P02 · Roof with upper exhaust; D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile; G1 · Door 1 OPTIX pane

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

Before you begin: No wet coating or adhesive may contact the pane or its unbonded strips.

1. Label and remove doors, hinges, pads, hasps, panes, foam, screens and removable captures. Keep hardware sets together and protect the acrylic masking.
2. Remove glue residue, lightly sand as required by the coating and veneer instructions and clean all dust with compatible methods. Do not round joint datums or change fitted gaps.
3. Mark bare metal-bearing footprints and service seats. Mask glue/bearing areas where required by the accepted construction and coating system.

Check before continuing: All surfaces are clean, labeled and ready for the accepted finish system.

Exact workshop reference · Show this stage in 3D

39. Seal the veneer substrate and wait

Parts: P02 · Roof with upper exhaust; P03 · Left side with lower inlet; D1A · Door 1 half-lapped stile

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

1. Follow the accepted PSA veneer supplier’s porous-substrate preparation. Oakwood’s guide calls for sealing porous wood before its PSA application.
2. Use the approved compatible sealer/topcoat combination and the thickness already accepted in the full-size trial. Keep metal bearing footprints and fastener service openings free of veneer.
3. Check the surface is flat, clean and fully suitable for adhesion before applying any veneer. A dry-feeling surface alone does not resolve compatibility or cure.

Check before continuing: Supplier-approved surface preparation and the recorded wait are complete.

Required wait: Oakwood states at least 24 hours after sealing; a longer coating or supplier requirement still governs.

Exact workshop reference · Show this stage in 3D

40. Fit separate veneer pieces to all exposed edges

Parts: P01 · Continuous floor; P02 · Roof with upper exhaust; P03 · Left side with lower inlet; D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile

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

Before you begin: Use protected hand placement and a supported sharp cutter; never slice toward the hand holding a narrow strip.

1. Use the grain-oriented rough pieces for roof/floor edges, side front/back edges, roof and vent reveals, fixed door-opening reveals and door edges.
2. Dry-place and label each piece before exposing adhesive. Use separate strips at square corners, the sloped latch edge and each removable seam; do not bridge from roof to side or door to frame.
3. Apply the accepted pressure along the grain, working from the centre outward. Trim in controlled scoring passes on support and ease only sharp veneer arrises.

Check before continuing: All visible edges have matching coverage without changing the service seams.

Required wait: Follow the accepted adhesive application and dwell requirements.

Exact workshop reference · Show this stage in 3D

41. Cover the roof, underside and exterior faces

Parts: P01 · Continuous floor; P02 · Roof with upper exhaust; P03 · Left side with lower inlet; P04 · Right side with lower inlet; P05 · Back

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

1. Apply the chosen species to the complete roof top, floor underside, side faces, back, fixed front faces and door faces using the assigned grain directions.
2. Keep one continuous roof-face grain layout around its aperture. Keep separate door rails and stiles and fully expose the named hardware seats and service heads.
3. Press and trim according to the accepted system. Inspect each corner, opening reveal and underside for exposed plywood, loose edges or a bridged removable joint.

Check before continuing: The exterior looks uniform and the agreed complete layer stays within its fit allowance.

Exact workshop reference · Show this stage in 3D

42. Apply the specified clear finish

Parts: P02 · Roof with upper exhaust; P03 · Left side with lower inlet; F05 · Front centre stile; D1A · Door 1 half-lapped stile

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

1. Use the accepted Varathane Triple Thick water-based satin system in the maker’s 60–90°F (15.6–32.2°C) application range and below 85% relative humidity, with required ventilation and protection.
2. Apply the specified coat and film thickness to the intended surfaces; the reference dry film is 0.003 in (0.08 mm). The conservative quantity includes faces, exterior preseal, veneer topcoat and trial reserve.
3. Keep the accepted face balance and avoid pooled finish at gaps, bearing seats and glazing contact areas. An extra coat changes thickness and purchasing allowance; recheck before adding it.

Check before continuing: Finish coverage and conditions are recorded, with no blocked seats or gaps.

Required wait: Maker reference: at least 2 hours before recoating, 48 hours before light use and 7 days to full cure at 70°F (21.1°C)/50% humidity. Cooler or more humid conditions extend times; full cure is required before glazing and use.

Exact workshop reference · Show this stage in 3D

43. Inspect cured layers and finish the final fit

Parts: D1A · Door 1 half-lapped stile; D1B · Door 1 half-lapped stile; F05 · Front centre stile; P02 · Roof with upper exhaust

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

1. After the required cure and adhesive dwell, measure the actual complete veneer layer and compare the full-size trial.
2. Dry-fit the doors, pads, hasps, roof and captures. Verify at least 1/16 in (1.59 mm) final door clearance everywhere and record the actual values; verify every covered reveal still admits its intended part.
3. If a gap closes, a bond lifts, a face bows or a plate loses bearing, stop and revise the affected geometry. Do not sand through veneer at random or force parts with screws.

Check before continuing: The cured finish and the actual fitted geometry agree.

Exact workshop reference · Show this stage in 3D

44. Reinstall screens, supports and roof

Parts: M01 · Roof screen blank; VM1 · Side inlet screen blank; VM2 · Side inlet screen blank; LB1 · Steel strip below left lamp area; LB2 · Steel strip below left lamp area; P02 · Roof with upper exhaust

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

1. Refit the labeled screens, recessed battens and steel supports on clean wood bearing lands. Keep the received, fitted bolt sets with their original stations.
2. Seat all 36 flush heads, inside washers and nylon locknuts; confirm closed covers have spare blind depth and remain secure. Use the accepted hand-controlled assembly, not an invented torque.
3. Refit the removable roof using its separate wood screws. Verify its panel sits flat, rib relief clears and every service head remains accessible.

Check before continuing: No wire point, projecting outside nut or uncovered inside thread remains.

Exact workshop reference · Show this stage in 3D

45. Rehang and operate both finished doors

Parts: H1-1_fixed · 1798A21 fixed leaf with knuckles; H1-1_moving · 1798A21 moving leaf with knuckles; D1A · Door 1 half-lapped stile; D2B · Door 2 half-lapped stile

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

1. Refit the bare bearing pads, hinges and hasps to their received-transferred holes. Support each leaf, insert the upper pin first, then the lower, without hammering a misaligned assembly.
2. Release each swivel and flap completely before moving its door. Open and close each through its intended range alone, then with the other open; check the actual hasp and hand paths.
3. Confirm final gaps, pin extraction space and independent hand-operated latching. Mark any door stop or user handling requirement established by the physical trial.

Check before continuing: Both finished doors operate and remain removable without rubbing or force.

Exact workshop reference · Show this stage in 3D

46. Fit clean panes, rear strips and removable caps

Parts: G1 · Door 1 OPTIX pane; G2 · Door 2 OPTIX pane; E1L · Door 1 plain EPDM rear cushion L; E1B · Door 1 plain EPDM rear cushion B; B1L · Door 1 separate flat cap L; B1B · Door 1 separate flat cap B

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

Before you begin: If it bows or rattles, resolve the actual stack and supplier advice; do not use extra torque as a correction.

1. Remove each supported door using the rehearsed pin sequence and lay it on a clean padded bench. Support the pane; remove masking after machining and cleanup. Use only acrylic-compatible cleaners.
2. Fit the actual pane inside the retained spacer opening with 1/8 in (3.18 mm) edge gaps. Place the accepted plain EPDM strips behind it, with no adhesive to the pane and no extra stacked layers.
3. Seat each labeled cap on its spacer and gently tighten the specified #6 screws. Check for pane bow, rattle, debris and edge contact. Rehang the glazed door with a helper, upper pin first, then lower; repeat the operation checks.

Check before continuing: Each pane has light cushion contact and can be removed without cutting adhesive.

Exact workshop reference · Show this stage in 3D

47. Set the optional fixture only after receiving checks

Parts: LB1 · Steel strip below left lamp area; LB2 · Steel strip below left lamp area; M01 · Roof screen blank

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

Before you begin: Do not place a fixture on unsupported mesh. The listed electrical maximum is not a recommended operating wattage or a thermal clearance.

1. This design provides one optional external fixture location centred 9 in (228.6 mm) from LEFT and 15 in (381 mm) from FRONT. Its rigid flat rim must contact both steel strips through the screen.
2. The source geometry allows a 5 1/2 in (139.7 mm)–6 in (152.4 mm) rim and at most 6 in (152.4 mm) overall diameter. Its proposed 2-pound (0.91 kg) assembled-weight ceiling is untested; weigh the actual fixture and bulb and obtain support/load acceptance.
3. Follow the exact fixture/bulb instructions for secure support, electrical limits and heat clearances. The right roof bay remains clear of heat equipment; establish the required shade and temperature gradient.

Check before continuing: Received fixture geometry, weight, secure support and commissioning plan are accepted.

Exact workshop reference · Show this stage in 3D

48. Commission the empty finished enclosure

Parts: P01 · Continuous floor; P03 · Left side with lower inlet; P04 · Right side with lower inlet; M01 · Roof screen blank

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

Before you begin: This dry indoor shell is not a water-holding, lined, outdoor, structural or animal-safety certification.

1. Before animals, complete the recorded species-specific checks for opening/mesh containment, ventilation, heat gradient, humidity, cleaning and door handling.
2. Keep dry substrate no higher than 3 in (76.2 mm) above the inside floor and a clear 2 in (50.8 mm) zone around each side inlet, unless an accepted coordinated species design requires a revision.
3. Verify the full base support and actual loaded stability. Run the actual equipment under supervision according to maker and qualified guidance, measuring all critical surfaces and air zones.

Check before continuing: The physical commissioning record is complete and accepted.

Exact workshop reference · Show this stage in 3D

49. Record inspection and repeatable maintenance

Parts: P02 · Roof with upper exhaust; G1 · Door 1 OPTIX pane; H1-2_pin · 1798A21 removable pin reference

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

1. Record actual material gauges, final gaps, fitted fixing lengths, suppliers, cure dates, assembled weight and all accepted hold decisions.
2. Inspect pins, screws, caps, bond edges, pane contact, wire edges and support during cleaning. Remove animals and disconnect/cool equipment before maintenance.
3. Use the demonstrated roof, inward screen-batten, supported door and pane removal paths. Recheck operation and containment after service; preserve this revision with its evidence and any recorded substitution.

Check before continuing: Maintenance can be repeated without guessing the construction or losing its record.

Exact workshop reference · Show this stage in 3D