Build the tall twin-door wooden enclosure

1. Plan full support, restraints and service space

Parts: P01 · Floor; RT · External rear restraint receiver

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

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

1. The bare case is 36 in (914.4 mm) wide × 24 in (609.6 mm) deep × 48 in (1219.2 mm) high. Maximum covered wood is 36.092 in (916.74 mm) × 24.092 in (611.94 mm) × 48.092 in (1221.54 mm); the rear receiver adds 3/4 in (19.05 mm) depth and hardware projects farther.
2. Provide level support beneath the entire finished floor. Record actual loaded weight and obtain an assessment of the support, stability and site wall attachment for both external restraints.
3. Reserve both outward door sectors, at least 16 in (406.4 mm) in front and 4 in (101.6 mm) above the upper hinge pin, with extra space for actual hands, tools and helpers. Rehearse roof lifting and a supported door-removal route.

Check before continuing: The support, wall attachment and maintenance routes are recorded.

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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: A reference picture or calculation does not close a physical acceptance hold.

1. Read H01–H06 before buying or making dependent cuts. Record real measurements and supplier or qualified decisions in the acceptance worksheet.
2. Choose one maple, white-oak or walnut system. Confirm veneer backing, adhesive, balancing method, preseal and finish compatibility. PSA means pressure-sensitive adhesive.
3. Keep the named product identities. A substitution requires revising affected cuts, holes, quantities, pictures and instructions together.

Check before continuing: Every input needed for the next operation is accepted.

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3. Measure and label the received stock

Parts: P03 · Left side; FA · Front outer stile; G1 · Door 1 OPTIX pane

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

1. Reference plywood thickness is 0.703 in (17.86 mm). Measure corners and centre of each sheet; cutting plans use a conservative 96 in (2438.4 mm) × 48 in (1219.2 mm) stock area.
2. Verify solid pine at 3/4 in (19.05 mm) × 5 1/2 in (139.7 mm) × 96 in (2438.4 mm) and the separate 1 1/2 in (38.1 mm) square stock. Full-width sill pieces need sound 5 1/2 in (139.7 mm) edges. Check acrylic, plain neoprene, mesh, steel, pads and all hardware.
3. Acclimate as suppliers require. Mark INSIDE, FRONT, LEFT or RIGHT, part ID, grain direction and the measuring corner. Save matching offcuts and reject damaged bearing areas.

Check before continuing: Received gauges, sound edges and datums are recorded.

Required wait: Use confirmed material acclimation requirements; no arbitrary duration is assumed.

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4. Prepare safe 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 short loose pieces through a planer or trap waste against a blade.

1. Use a flat padded bench, clamps, straight cauls and supported infeed/outfeed. A caul spreads clamp pressure. Rehearse the largest panel and tall empty-case turn with helpers.
2. Use the actual tool guards, riving knife, push aids and minimum feed lengths. Mill narrow strips from long supported stock with a guarded carrier or use a machining service.
3. Clamp drill/router work and waste to a backer. Disconnect power before setting cutters, guides or depth stops.

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

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5. Trial pilots, clearance holes and head seats

Parts: Accepted material samples and the named workshop setup

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

Before you begin: Do not enlarge factory hinge or hasp holes to force an unsuitable screw to fit.

1. A clearance hole lets the first member pass freely over the screw. A smaller pilot guides its thread in the receiving wood. Trial the actual screw in matching offcuts.
2. Reference #6 clearance/pilot diameters are 5/32 in (3.97 mm) / 3/32 in (2.38 mm); #8 uses 11/64 in (4.37 mm) / 7/64 in (2.78 mm); #10 wood screws use 13/64 in (5.16 mm) / 1/8 in (3.18 mm). Actual root diameter, wood and trial results govern.
3. Screen screws use 1/4 in (6.35 mm) through holes and 82-degree flat-head seats. Include the drill point in stopped depth and retain at least 1/16 in (1.59 mm) sound wood beyond each tip.

Check before continuing: Heads seat without splits, crushed bearing wood or exposed points.

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6. Trial the hinges, bearing pads and hasps

Parts: H11_fixed · 1798A21 fixed leaf with knuckles; H11_moving · 1798A21 moving leaf with knuckles; SP-H11-fixed · Rigid full-leaf bearing pad H11 fixed; SP-H11-moving · Rigid full-leaf bearing pad H11 moving

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

Before you begin: Six hinges are specified; their count is not a proven tall-door weight rating.

1. Trial the exact 1798A21 hinge on matching laminated fixed/moving offcuts, with equal 3 in (76.2 mm) × 1 1/16 in (26.99 mm) × 1/8 in (3.18 mm) rigid aluminium pads. Minimum reference pad thickness is 7/64 in (2.78 mm); custom mounting acceptance remains H02.
2. Keep the barrel forward and the pin removable upward. Transfer actual holes and trial the listed #8 × 1 1/4 in (31.75 mm) heads. Both leaves and pads need full bare-wood bearing and adequate screw engagement.
3. Trial each N305-979 narrow base on a moving 2 in (50.8 mm) source latch stile, and its square swivel plate on the fixed 2 1/2 in (63.5 mm) centre member. Account for later trimming and veneer; support every hole and plate.

Check before continuing: Actual seating, margins, head fit, pin path and supported swing are accepted.

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7. Make a full-size laminated-door veneer trial

Parts: D1A · Door 1 A; D1B · Door 1 B; D1E · Door 1 E; D1G · Door 1 G

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

1. Use reserved pine to make a complete representative tall door with both staggered layers. Apply the accepted face, edge, adhesive, sealer and finish system; a small coupon cannot prove full-door balance.
2. Follow supplier balancing, pressure and dwell instructions. Measure the complete cured layer including adhesive and coating: no specified face may exceed 0.046 in (1.17 mm).
3. Record flatness, bond and hardware operation under intended conditions. Any extra balancing layer or changed stock gauge requires a coordinated revision.

Check before continuing: The cured full-size trial remains flat and fits the accepted hardware.

Required wait: Supplier adhesive dwell and full coating cure are separate waits.

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8. Trial the solid-pad glazing stack after cure

Parts: Q1L · Door 1 spacer L; B1L · Door 1 retaining bead L; G1 · Door 1 OPTIX pane; N1FL · Door 1 F cushion L; N1RL · Door 1 R cushion L

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

Before you begin: No adhesive foam, forced compression, glued pane or water-seal claim.

1. Build a matching sample with the separate rear spacer and 1/4 in (6.35 mm) retaining bead. Mill from 3/8 in (9.53 mm) rough spacer stock; reference bare depth is 0.351 in (8.92 mm).
2. The finished contact distance must match actual acrylic plus two plain solid neoprene faces. Reference 0.22 in (5.59 mm) pane plus two 1/16 in (1.59 mm) pads totals 0.345 in (8.76 mm); the extra 0.006 in (0.15 mm) bare depth allows 0.003 in (0.08 mm) finish on both opposing wood surfaces.
3. Trial fully cured surfaces with light contact, no bow or forced compression, and 1/8 in (3.18 mm) free pane-edge allowance. Resolve real coating/pad thickness and compatibility before dependent cuts.

Check before continuing: The bead stops on its wood spacer while the pane remains supported and unbowed.

Required wait: Complete coating cure before measuring the contact fit.

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9. Allocate and rough-cut labeled blanks

Parts: P01 · Floor; P02 · Roof; P03 · Left side; P04 · Right side; P05 · Back

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

1. Follow the numbered stock layouts with their exact coordinates, grain, trim and kerf. The reference wood kerf is 1/8 in (3.18 mm); revise allocation for the actual blade or defective stock.
2. Keep installed blanks separate from two complete trial pine boards, the solid-stock trial and the full-size veneer trial. The full-width sill board has end trim but no spare rip width.
3. Pine strip allocations include 1/8 in (3.18 mm) extra rip width beyond the cut table’s pre-fit sizes. Trim to those sizes before final fitting. Make long supported cuts before narrowing strips; label each blank. Exact final decimals govern fitting; rounded tape equivalents are only orientation.

Check before continuing: Every installed part and trial allowance has a feasible assigned blank.

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10. Fit the five case panels

Parts: P01 · Floor; P02 · Roof; P03 · Left side; P04 · Right side; P05 · Back

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

1. Fit P01 floor and P02 roof at 36 in (914.4 mm) × 24 in (609.6 mm). P03/P04 sides are 24 in (609.6 mm) deep × 46.594 in (1183.49 mm) high between the reference 0.703 in (17.86 mm) floor and roof.
2. Fit P05 back between the actual sides: reference 34.594 in (878.69 mm) wide × 46.594 in (1183.49 mm) high. Transfer the measured clear gaps with a story stick, a strip marked directly from the assembly.
3. Check the bare width/depth/height chains close at 36 in (914.4 mm) / 24 in (609.6 mm) / 48 in (1219.2 mm). Keep joint edges square and remove splinters without rounding the measuring faces.

Check before continuing: The dry panels close to the intended bare envelope.

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11. Cut the two roof openings

Parts: P02 · Roof

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

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

1. Mark each opening 13 1/4 in (336.55 mm) wide × 12 in (304.8 mm) deep. The left opening starts at X = 4 in (101.6 mm) and Y = 5 in (127 mm); the right starts at X = 18 3/4 in (476.25 mm) and Y = 5 in (127 mm), from outside LEFT and FRONT.
2. Preserve the 1 1/2 in (38.1 mm) centre roof bridge. Clamp both the roof and waste; use supported starter and guided cuts for the actual saw/router.
3. Compare diagonals and the two openings. Dry-position the single 29 in (736.6 mm) × 13 in (330.2 mm) mesh blank below both, beginning at X = 3 1/2 in (88.9 mm) and Y = 4 1/2 in (114.3 mm).

Check before continuing: Both openings, border and centre bridge match their own datums.

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12. Cut matching side ventilation openings

Parts: P03 · Left side; P04 · Right side

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

1. Mark each 12 in (304.8 mm)-long × 2 in (50.8 mm)-high opening, starting 5 in (127 mm) behind the side FRONT edge and 6.797 in (172.64 mm) above the panel bottom.
2. With the reference floor fitted, the opening bottom is 7 1/2 in (190.5 mm) above floor underside. Keep panel-local and assembly datums distinct.
3. Support the waste during cutting. Compare paired sides and dry-position each revised 13 in (330.2 mm) × 3 1/2 in (88.9 mm) mesh blank and four inside battens.

Check before continuing: The two apertures and mesh overlaps agree.

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13. Fit cleats, ledgers and the bearing column

Parts: CLB · L side B cleat; CRB · R side B cleat; CFB · F floor cleat; CBB · B floor cleat; RF · F roof ledger; RB · B roof ledger; CCa · Front bearing column layer A; CCb · Front bearing column layer B; RC · Roof centre rib

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

1. A cleat receives joint screws; a ledger supports a horizontal member. Fit the named 1 1/2 in (38.1 mm) square pine cleats and ledgers to their actual gaps. Use the complete cut schedule.
2. Glue two 2 1/2 in (63.5 mm)-wide × 3/4 in (19.05 mm)-thick CC layers into a 1 1/2 in (38.1 mm)-deep column. Reference length is 42.26 in (1073.4 mm) between the front floor cleat and RF ledger. Fit actual bearings without gaps.
3. RC is the fixed central roof rib, reference 21.797 in (553.64 mm) long × 1 1/2 in (38.1 mm) wide × 1.334 in (33.88 mm) high before its screen relief. Keep it distinct from the removable roof captures and optional fixture strips.

Check before continuing: Every intended bearing fits fully without a hidden short part.

Required wait: Keep the laminated column clamped for the maker-required period: stressed joints require 24 hours. Do not stress it for at least 24 hours; allow longer when conditions require. Use the glue conditions explained in OP15.

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14. Dry-stack the fixed front layers

Parts: FA · Front outer stile; FB · Front outer stile; FC · Front sill rail; FD · Front head rail; FE · Front centre stile; FF · Rear centre stile

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

1. Front FA/FB are full-height outer stiles, the vertical members. Fit FC sill and FD header between them; FE fills between those rails at centre.
2. The rear layer staggers the joints: FF is full height at centre, FGL/FGR are sill halves and FHL/FHR header halves, with FI/FJ between the rear rails.
3. Dry-stack square and flush on a flat bench. Each opening is reference 13.547 in (344.09 mm) wide × 38.594 in (980.29 mm) high. Label the layer and orientation before separating.

Check before continuing: The two flush openings are square and all joints overlap correctly.

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15. Glue and screw the fixed front

Parts: FA · Front outer stile; FB · Front outer stile; FC · Front sill rail; FD · Front head rail; FE · Front centre stile; FF · Rear centre stile

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

1. Apply Titebond III only to clean bare mating faces. Use the maker spread and working time; the conservative application minimum is 47°F (8.3°C).
2. Clamp both layers flat and square with cauls. Install the 32 rear-entry #8 × 1 1/4 in (31.75 mm) frame-lamination screws at their station coordinates; clear the rear layer and stop the pilot in the front layer.
3. Remove squeeze-out from later pane, veneer and hardware areas. Recheck diagonals and flatness before leaving the assembly clamped.

Check before continuing: All overlapping joints seat, screw tips are buried and the frame remains flat.

Required wait: Maker guidance: 30–60 minutes clamping for unstressed joints; stressed joints require 24 hours. Do not stress these assemblies for at least 24 hours; cold conditions can require longer.

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16. Cut and dry-stack both laminated doors

Parts: D1A · Door 1 A; D1B · Door 1 B; D1C · Door 1 C; D1D · Door 1 D; D1E · Door 1 E; D1F · Door 1 F; D1G · Door 1 G; D1H · Door 1 H

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

1. Each door uses two 3/4 in (19.05 mm) pine layers. Front rails C/D fit between full-height A/B stiles. Rear full-width rails E/F bridge those joints; short rear stiles G/H fit between them.
2. Keep the 2 in (50.8 mm) latch stile at centre and 1 1/2 in (38.1 mm) hinge stile outside. Mirror that relationship on Door 2. These are staggered laminations, not half-laps.
3. Dry-stack the original 13.297 in (337.74 mm) × 38.344 in (973.94 mm) outside frame with its 9.797 in (248.84 mm) × 35.344 in (897.74 mm) viewing opening. Fit the outside perimeter only after glue cure.

Check before continuing: Both layer stacks are square, flush and correctly handed.

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17. Glue and fasten the tall door layers

Parts: D1A · Door 1 A; D1B · Door 1 B; D1E · Door 1 E; D1F · Door 1 F; D2A · Door 2 A; D2B · Door 2 B

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

1. Glue the bare mating layers and clamp each frame flat on cauls. Compare diagonals without forcing a twisted member into position.
2. Install twelve #8 × 1 1/4 in (31.75 mm) rear-entry lamination screws per leaf at the listed DL stations. Make rear clearance holes and stopped pilots with the pane absent.
3. Clear squeeze-out from future contacts. Keep viewing opening datums and the wide centre latch stiles unchanged.

Check before continuing: Each complete leaf stays flat, with seated overlapping joints and buried tips.

Required wait: Keep the confirmed clamp and 24-hour minimum no-stress wait before trimming or hanging.

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18. Fit bare gaps for all veneer layers

Parts: D1A · Door 1 A; D1B · Door 1 B; D1E · Door 1 E; D1F · Door 1 F; FE · Front centre stile

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

Before you begin: The unmodified source 1/8 in (3.18 mm) gaps do not provide sufficient full-veneer allowance.

1. After cure, remove 1/16 in (1.59 mm) from the original hinge edge and each top/bottom edge, and 1/32 in (0.79 mm) from the latch edge. Preserve the viewing and rear-glazing datums.
2. Reference fitted bare leaves are 13.20325 in (335.36 mm) wide × 38.219 in (970.76 mm) high. Fit actual openings for 3/16 in (4.76 mm) hinge/top/bottom gaps and 5/32 in (3.97 mm) latch gaps.
3. Two maximum 0.046 in (1.17 mm) opposing finished layers leave 0.06425 in (1.63 mm) at the latch. Verify at least 1/16 in (1.59 mm) final gap everywhere, with separate animal containment acceptance.

Check before continuing: The bare perimeter allows the complete accepted veneer and finish.

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19. Bevel each rear latch edge

Parts: D1B · Door 1 B; D1H · Door 1 H; D2A · Door 2 A; D2G · Door 2 G

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

1. A back bevel slopes inward at the rear while preserving the front edge. Trial a 6-degree bevel on the left door’s right edge and the right door’s left edge.
2. Across the full 1 1/2 in (38.1 mm) depth, reference rear setback is about 0.158 in (4.01 mm). Preserve the laminated bond, front size, hasp bearing and glazing spacer positions.
3. Dry-swing supported leaves on accepted hardware. Later cover each sloping edge with its own veneer strip and trim it without bridging a joint.

Check before continuing: The rear latch edges clear without shortening the front faces.

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20. Make the spacers, beads and acrylic panes

Parts: Q1L · Door 1 spacer L; Q1B · Door 1 spacer B; B1L · Door 1 retaining bead L; B1B · Door 1 retaining bead B; G1 · Door 1 OPTIX pane

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

Before you begin: Thin milling needs a guarded carrier or machining service, not short loose feeds.

1. Mill supported long pine stock before ripping: spacers are 3/4 in (19.05 mm) wide and begin at 3/8 in (9.53 mm) rough thickness; beads are 1 1/4 in (31.75 mm) wide × 1/4 in (6.35 mm) thick. Use the accepted cured-stack depth.
2. Each reference pane is 10.547 in (267.89 mm) wide × 36.094 in (916.79 mm) high × 0.22 in (5.59 mm) thick. Confirm its actual pocket is 1/4 in (6.35 mm) larger overall in each direction, leaving 1/8 in (3.18 mm) at each edge.
3. Keep acrylic masking while cutting on a supported setup recommended by its maker. Clean debris with compatible products. Never drill through the pane.

Check before continuing: The correctly labeled panes fit freely inside their spacer frames.

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21. Transfer and trial the bead screws

Parts: Q1L · Door 1 spacer L; Q1R · Door 1 spacer R; B1L · Door 1 retaining bead L; B1R · Door 1 retaining bead R; B1B · Door 1 retaining bead B; B1T · Door 1 retaining bead T

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

1. Lay the supported door rear upward. Dry-fit spacers, actual solid pads and pane, then fit beads so their wood faces stop on the spacer faces.
2. Each leaf has ten side stations and two additional centre rail stations: twelve #6 × 1 1/4 in (31.75 mm) screws per door, twenty-four total. Use DG/DGT station coordinates.
3. Remove the pane before drilling. Countersink the bead, clear the first members and stop the receiver pilot. Trial light contact, free edges and later pane removal without glue.

Check before continuing: All bead screws are accessible and the pane remains unbowed.

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22. Cut the roof and side capture battens

Parts: RB1L · Roof capture batten; RB1R · Roof capture batten; RB2L · Roof capture batten; RB2R · Roof capture batten; RB3 · Roof capture batten; RB4 · Roof capture batten

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

1. Cut the six 3/4 in (19.05 mm)-thick roof battens to the schedule, keeping the left steel-bearing halves distinct. Leave the centre split around fixed rib RC.
2. Each side has two 14 in (355.6 mm)-long × 1 1/4 in (31.75 mm)-wide lower/upper battens and two 2 in (50.8 mm)-long × 1 in (25.4 mm)-wide end battens. The wider outer strips preserve full washer bearing at revised drill positions.
3. Dry-position each piece against its own opening. Mark the plywood-facing face before machining its wire relief.

Check before continuing: All capture parts have the correct IDs, handed positions and full overlap.

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23. Machine fitted wire reliefs and wood lands

Parts: RB1L · Roof capture batten; RB3 · Roof capture batten; VLB · L vent capture B; VLF · L vent capture F; RC · Roof centre rib

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

Before you begin: Actual wire/crossing thickness controls this dependent cut; H03 remains open.

1. Measure actual welded crossing thickness. Reference relief is 3/32 in (2.38 mm) deep; it must clear the real wires while the outer wood lands seat directly against the case.
2. Route the specified partial-width reliefs with the piece clamped to a carrier/backer. Preserve the 0.494 in (12.55 mm) reference outer wood land. Do not groove away the entire bearing face.
3. Relieve the middle of RC under the crossing cloth but retain its solid end roof bearings. Trial every batten and rib interface with received mesh; no screw pressure should close a wire-height gap.

Check before continuing: All wood lands seat positively and no wire is crushed.

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24. Cut and identify the three mesh blanks

Parts: M01 · Roof mesh blank; ML · L vent mesh; MR · R vent mesh

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

Before you begin: Wear suitable hand/eye protection for sharp mesh; keep gloves away from powered rotating tools.

1. Cut roof M01 at 29 in (736.6 mm) × 13 in (330.2 mm). Cut ML/MR side blanks at 13 in (330.2 mm) × 3 1/2 in (88.9 mm); keep each flat and square without damaged welds.
2. Remove projecting sharp ends where the finished captured edge requires it. Keep the specified overlaps and register the actual grid against the station plan.
3. Reference 0.541 in (13.74 mm) pitch and 0.041 in (1.04 mm) wire describe nominal 1/2 in (12.7 mm) clear cells. Real cloth can differ; do not drill through a welded wire to force the drawing to fit.

Check before continuing: Mesh fits each relief with captured edges and clear planned screw passages.

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25. Fit and drill the two roof steel strips

Parts: LB1 · Steel strip below the left lamp area; LB2 · Steel strip below the left lamp area; RB1L · Roof capture batten; RB2L · Roof capture batten

Tools / setup: Metal vise, supported saw/drill, 1/4-inch bit, files and caliper

Before you begin: Reference strip geometry is not a tested roof or fixture load rating.

1. Cut two 14 in (355.6 mm) × 1 in (25.4 mm) × 1/8 in (3.18 mm) solid steel strips from the named bar. Deburr faces and ends; transfer two 1/4 in (6.35 mm) holes 1/2 in (12.7 mm) from each end, 13 in (330.2 mm) apart.
2. The revised strip centre axes are X = 8.262 in (209.85 mm) and 12.049 in (306.04 mm). Transfer those positions together to the matching left battens and roof stations.
3. Mill the received steel end seats to maintain its reference top elevation. Revised reference pockets are 0.209 in (5.31 mm) deep, leaving 0.541 in (13.74 mm) wood beneath; this remaining section needs physical/qualified acceptance.

Check before continuing: Both strips seat fully without rocking and the four bolt paths align.

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26. Transfer the flush screen fixing stations

Parts: P02 · Roof; P03 · Left side; P04 · Right side; M01 · Roof mesh blank; ML · L vent mesh; MR · R vent mesh

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

1. Clamp each real capture stack and transfer the current station coordinates: twenty-two roof and eight per side. Original IDs are labels; use their current X/Y/Z values.
2. Prove every 1/4 in (6.35 mm) passage clears an open wire cell and every inside 1 in (25.4 mm) washer seats completely on wood. The roof steel positions move with the revised axes.
3. Drill with backing, then trial 82-degree flat seats from outside in sound plywood. Leave a veneer service opening around each head; the head must bear in wood, not soft veneer.

Check before continuing: All thirty-eight passages, outside seats and inside bearing areas agree.

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27. Fit retained bolts and closed inside covers

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: A cover is not a substitute for the locknut. No torque or clamp-load value is assumed.

1. Buy #10-24 × 2 1/2 in (63.5 mm) flat-head screws. Reference fitted length is 1 7/8 in (47.63 mm) for the 1.453 in (36.91 mm) wood grip, inside washer, nylon locknut and closed cover.
2. Measure actual washer, locknut and cap depth before cutting. Fully engage nylon, leave at least two complete threads beyond it, and keep at least 1/32 in (0.79 mm) unused blind depth in the seated cover.
3. Trial on an offcut. Hold securely for trimming, deburr and clean threads; retain the locknut while seating the cover. Use two fitting hand tools and verify access.

Check before continuing: The cover seats without bottoming and no thread remains exposed.

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28. Assemble the two side captures

Parts: P03 · Left side; ML · L vent mesh; VLB · L vent capture B; VLT · L vent capture T; VLF · L vent capture F; VLR · L vent capture R

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

1. Lay each side exterior down on protection. Seat the mesh in its relief and fit all four inside battens with intact wood lands against the panel.
2. Insert the eight flush outside screws and install inside washers, nylon locknuts and fitted closed covers. Keep the actual wire uncut at each screw axis.
3. Check no sharp edge, wire distortion, loose screen or exposed tail. Keep the side service path accessible; do not glue the removable captures.

Check before continuing: Each side screen is retained and can be serviced with the agreed tools.

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29. Fit the side and rear cleats

Parts: P03 · Left side; P04 · Right side; CLB · L side B cleat; CLT · L side T cleat; CRB · R side B cleat; CRT · R side T cleat; CLV · Rear corner cleat; CRV · Rear corner cleat

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

1. Align side floor and top cleat edges with the actual panel edges and locate rear corner cleats from their specified datums. Clamp the empty panels securely.
2. Use current SIDE/EDGE station coordinates and the indicated #8 × 1 3/4 in (44.45 mm) screws. Clear first members and stop the pilot in the actual solid receiver.
3. Keep the front/rear receptor rows at their measured levels. Do not pull a bowed panel flat with screw force or lose the 36 in (914.4 mm) bare width.

Check before continuing: Cleats are square, correctly placed and have buried screw points.

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30. Fit the back and horizontal ledgers

Parts: P05 · Back; CBB · B floor cleat; RF · F roof ledger; RB · B roof ledger; CLV · Rear corner cleat; CRV · Rear corner cleat

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

1. Fit P05 between the sides with its front/rear orientation correct. Install the lower rear cleat and the measured RF/RB roof ledgers from the support drawing.
2. Transfer actual wood receiver centres to the back screw rows and use their listed lengths. Check the rear restraint row enters RB through the correct stack.
3. Keep the RF relief and front column bearings oriented as drawn. Check that the case remains square on the supported bench.

Check before continuing: The back, cleats and ledgers agree with actual mating parts.

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31. Attach the fully supported floor

Parts: P01 · Floor; CFB · F floor cleat; CBB · B floor cleat; CLB · L side B cleat; CRB · R side B cleat

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

Before you begin: Do not turn a glazed or loaded enclosure for this work.

1. Fit front floor cleat CFB between the side cleats. Clamp the floor to continuous support with the case square.
2. With helpers, turn the empty assembly onto padding for safe perpendicular drilling. Install fourteen #8 × 1 3/4 in (44.45 mm) floor screws from underneath at FLOOR stations.
3. Check each actual receiver, stopped pilot and buried tip before returning the empty case upright. The finished enclosure needs full-footprint support.

Check before continuing: The floor is square and every listed connection lands in sound receiving wood.

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32. Install the cured front and bearing column

Parts: FA · Front outer stile; FB · Front outer stile; FC · Front sill rail; FD · Front head rail; FE · Front centre stile; CCa · Front bearing column layer A; CCb · Front bearing column layer B; CFB · F floor cleat; RF · F roof ledger

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

1. Fit the cured front flush with the side fronts and floor. The sill top remains 5 1/2 in (139.7 mm) above the inside floor.
2. Seat the laminated CC column fully on CFB and beneath RF. Reference column length 42.26 in (1073.4 mm) is fitted to the actual bearing gap; never hide a short bearing with screws.
3. Use the FRONTREC and five COLUMN #8 × 2 1/2 in (63.5 mm) stations. Clamp square and verify both openings and diagonals before drilling.

Check before continuing: The front is square and the column has full end contact.

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33. Fit the fixed central roof rib

Parts: RC · Roof centre rib; RF · F roof ledger; RB · B roof ledger; CCa · Front bearing column layer A

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

Before you begin: Do not support a heat fixture on this central wood rib.

1. Seat RC across RF and RB at the case centre. Its reference top reaches the roof underside on solid lands outside the mesh; the middle relief clears the cloth.
2. Install the two RIBBEAR #8 × 2 1/2 in (63.5 mm) screws downward at X = 18.3 in (464.82 mm), Y = 2 in (50.8 mm) and 22.797 in (579.04 mm). Those paths remain outside the mesh blank.
3. Recheck end contact, relief clearance and covered screw tips. RC stays with the case when the roof panel is removed.

Check before continuing: The rib is fixed to its ledgers and supports the intended roof bearings.

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34. Assemble the removable roof capture

Parts: P02 · Roof; M01 · Roof mesh blank; RB1L · Roof capture batten; RB2L · Roof capture batten; LB1 · Steel strip below the left lamp area; LB2 · Steel strip below the left lamp area

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

1. Support P02 face down on protection. Seat the single mesh blank, the two left steel strips and all six marked capture battens.
2. Fit twenty-two flush outside screws with inside washers, nylon locknuts and closed covers. Four stations also pass through the steel end bores.
3. Check every wood land seats, steel ends bear fully, caps have spare internal depth and the centre split clears fixed RC. Keep all service fixings accessible.

Check before continuing: The roof assembly has no loose screen, crushed wires, rocking strips or exposed threads.

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35. Trial-fit the roof to the complete case

Parts: P02 · Roof; RC · Roof centre rib; RF · F roof ledger; RB · B roof ledger

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

1. Lower the supported roof onto the case and fixed rib without trapping mesh, cables or tools. Confirm full intended bearings and the two openings.
2. Use the ROOF and ROOFHEAD wood-screw stations; clear the roof and pilot only the actual receivers. Do not add roof-to-rib screws through the mesh.
3. Trial roof removal again. Keep its seam unglued and preserve separate veneer edges so removal does not tear the finish.

Check before continuing: The roof seats squarely and can be removed independently.

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36. Make and fit the twelve hinge pads

Parts: SP-H11-fixed · Rigid full-leaf bearing pad H11 fixed; SP-H11-moving · Rigid full-leaf bearing pad H11 moving; H11_fixed · 1798A21 fixed leaf with knuckles; H11_moving · 1798A21 moving leaf with knuckles

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

1. Cut twelve full-leaf 3 in (76.2 mm) × 1 1/16 in (26.99 mm) rigid aluminium pads from the allocated bars; two more pad blanks are reserved for trials. Deburr all edges.
2. Transfer each received leaf’s holes onto its matching pad. Maintain at least 7/64 in (2.78 mm) thickness and full bare-wood bearing under both fixed and moving leaves.
3. Mark pads and leaves as pairs. Do not hide an uneven seat with adhesive or veneer; receive qualified/supplier acceptance of the custom support and engagement.

Check before continuing: All six hinge pairs seat evenly with matching supported pads.

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37. Hang the two supported tall doors

Parts: H11_fixed · 1798A21 fixed leaf with knuckles; H12_fixed · 1798A21 fixed leaf with knuckles; H13_fixed · 1798A21 fixed leaf with knuckles; D1A · Door 1 A

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

Before you begin: Support door weight before withdrawing any pin; never rely on the last loose hinge.

1. With a helper supporting each leaf, hold its finished bare gap spacers in the square opening. Align all three hinges on one straight axis.
2. Retain hinge centres at 10.328 in (262.33 mm), 25 1/2 in (647.7 mm) and 40.672 in (1033.07 mm) above floor underside. Use thirty-six #8 × 1 1/4 in (31.75 mm) hinge screws through the accepted heads, pads and stopped pilots.
3. Trial independent outward swing and supported pin removal with the roof fitted. Keep at least 4 in (101.6 mm) extraction clearance above the upper pin; actual pin/tool lengths govern.

Check before continuing: All hinges share an axis, tips remain buried and neither tall leaf binds.

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38. Transfer and fit the independent hasps

Parts: FE · 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

1. Put the narrow hinged bases on the moving latch stiles and square swivel plates on fixed FE. Left swivel centre: X = 17 19/32 in (446.88 mm), Z = 23 in (584.2 mm); right: X = 18 13/32 in (467.52 mm), Z = 29 in (736.6 mm).
2. Transfer the received seven-hole arrangement for each hasp, with full plate bearing and sound margins. Install fourteen #10 × 5/8 in (15.88 mm) screws at the accepted reference stations.
3. Turn one swivel to align with its slot, lift that flap fully outward, then open its own leaf while the other stays latched. Repeat the opposite side; no key is needed for everyday operation.

Check before continuing: Both closures secure and release independently without forcing the frame.

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39. Fit the external restraint receiver

Parts: RT · External rear restraint receiver; P05 · Back; RB · B roof ledger

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

1. RT is an external 31.594 in (802.49 mm) × 2 1/2 in (63.5 mm) × 3/4 in (19.05 mm) pine receiver. Position its bottom at Z = 43.963 in (1116.66 mm), with the horizontal ends aligned to the rear ledger span.
2. Use four RESTRAINTREC #8 × 2 1/2 in (63.5 mm) screws at X = 6 in (152.4 mm), 14 in (355.6 mm), 22 in (558.8 mm) and 30 in (762 mm), Z = 45.213 in (1148.41 mm). They pass through RT and P05 into RB; transfer the actual receiver centre before drilling.
3. Keep RT’s attachment footprint bare against the back. Trial the real restraint brackets on an offcut before final receiver drilling; their final bare bearing seats depend on the received kit.

Check before continuing: RT bears fully and all four screws enter sound RB with covered tips.

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40. Rehearse the two external restraint kits

Parts: RT · External rear restraint receiver

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

Before you begin: No kit catalogue rating is transferred to this unbuilt shell. Unknown walls remain a hold.

1. Receive two complete Hillman 9976524 kits. Identify their furniture brackets, wall brackets, cable, clevis pins, cotter pins and the specified screws.
2. Use the manufacturer’s actual stud-wall method with a verified wall/support. Trial furniture bracket placement and 5/8 in (15.88 mm) screws on matching RT stock, preserving a safe back cover.
3. Record the site-specific bracket positions, wall/stud assessment and access for later release. Keep every bracket and cable outside the containment shell; revise the plan for a different wall construction.

Check before continuing: A complete accepted anchorage plan exists before the tall enclosure enters service.

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41. Check the complete uncoated dry assembly

Parts: P02 · Roof; G1 · Door 1 OPTIX pane; G2 · Door 2 OPTIX pane; RT · External rear restraint receiver

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

1. Check square, flatness, bearings, all screw receivers, captured mesh edges and retained tails. Record actual diagonal differences and investigate anything beyond the planned 1/16 in (1.59 mm) comparison target.
2. Trial both doors, their independent hasps and supported pin extraction. Trial pane/bead and screen removal with appropriate helpers and no animals or equipment inside.
3. Mark any interference and revise the affected specification before finishing. Do not hide binding, weak bearing or uncertain anchorage under veneer.

Check before continuing: The actual dry construction and all planned service paths are accepted.

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42. Disassemble and label for finishing

Parts: P01 · Floor; P02 · Roof; D1A · Door 1 A; G1 · Door 1 OPTIX pane

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

1. Photograph the accepted fit and label mating parts, shims, pads and hardware. Support doors and panes during removal.
2. Remove glazing, cushions, hardware and captures as needed for access. Keep screws paired with existing holes; remove temporary trial hardware.
3. Store acrylic masked on clean support and protect wire/metal from wet coating. Preserve labels and avoid sanding away fitted datums.

Check before continuing: All parts are identified and protected for finishing.

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43. Prepare the wood and approved veneer surfaces

Parts: P03 · Left side; FA · Front outer stile; D1A · Door 1 A

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

Before you begin: Confirm cleaner and finish suitability for intended exposure; no animal-contact approval is inferred.

1. Follow the coating and veneer makers’ preparation instructions. Sand with grain on supported wood, remove dust and correct contamination before coating.
2. Mask bare structural glue/contact surfaces, receiver footprints and metal bearing seats. Keep service holes accessible and do not round the fitted door edges.
3. Prepare matching coupons along with the real parts so finish thickness, adhesion and required waits can be tracked.

Check before continuing: Surfaces are clean, compatible and ready for the confirmed system.

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44. Preseal and wait for the veneer substrate

Parts: P03 · Left side; P02 · Roof; D1A · Door 1 A

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

1. Use only the supplier-accepted preseal beneath the selected pressure-sensitive veneer. Keep the substrate smooth, sound and free of dust or silicone.
2. Apply and wait exactly as the veneer and coating suppliers require before bonding. The complete preseal/adhesive/backer/veneer/topcoat stack must stay within the accepted limit.
3. Recheck the cured trial coupon and the full-size door balance trial. Do not bond the production skins over a tacky or incompatible surface.

Check before continuing: The presealed substrate has reached the supplier-approved bonding condition.

Required wait: Use confirmed preseal cure before PSA application, separate from later topcoat cure.

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45. Apply the full exterior face veneer

Parts: P02 · Roof; P03 · Left side; P04 · Right side; P05 · Back; FA · Front outer stile; D1A · Door 1 A

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

1. Choose one species and use the exact V-part schedule. Align grain along each part’s assigned axis. Keep roof grain continuous on a flat plane; no raised or distorted texture is intended.
2. Cut the allocated oversize pieces, dry-register them and follow the veneer maker’s liner removal, pressure and scraper method without trapping air.
3. Cover roof, exterior walls, frame faces and underside. Keep separate removable seams and hardware bearing/service seats open. At RT, transfer its finished veneered outline to the back skin and leave a 1/64 in (0.4 mm) service seam all around; the reference opening is 31.68625 in (804.83 mm) × 2.59225 in (65.84 mm). Keep the receiver-to-back wood bearing bare.

Check before continuing: The faces are flat, bonded and correctly oriented without bridged service joints.

Required wait: Observe the supplier’s bonding pressure and dwell requirements; do not assume instant full strength.

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46. Finish every exposed edge and reveal

Parts: P02 · Roof; P03 · Left side; RT · External rear restraint receiver; D1A · Door 1 A; D1B · Door 1 B

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

1. Apply the separate edge and opening-reveal strips so plywood laminations and mixed bare edges are covered, including roof borders, door perimeters and the visible RT receiver.
2. Trim to actual parts with a sharp supported knife or approved trimming tool. Keep each bevel strip on its own sloping face and never bridge the roof seam or door clearance.
3. Leave the actual bare metal bearing pads, restraint bracket seats and fixing access openings functional. Recheck no edge lifts and the full cured layer remains at most 0.046 in (1.17 mm).

Check before continuing: Visible exterior wood is uniform; RT edge skins clear the back veneer by the planned 1/64 in (0.4 mm) service seam.

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47. Apply the accepted finish and allow full cure

Parts: P01 · Floor; P02 · Roof; D1A · Door 1 A; RT · External rear restraint receiver

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

Before you begin: Indoor non-immersed scope; no standing water, outdoor exposure or direct fixture hotspot approval.

1. Apply the selected Varathane Triple Thick satin according to current maker instructions, within 60–90°F (15.6–32.2°C) and below 85% relative humidity with suitable ventilation.
2. This revision allocates five quart cans including area/trial reserve; the listing sells two-can packs, so buy three packs. Recalculate for extra coats or a changed system.
3. Record last application/repair, temperature and humidity. Keep acrylic, neoprene, metal seats and threaded parts free of wet finish. Inspect and repair edges before the cure clock is considered complete.

Check before continuing: All surfaces and repairs are fully cured and the receiving coupon still meets fit limits.

Required wait: Maker full cure is seven days at 70°F (21.1°C) / 50% RH with ventilation; adverse conditions can require longer. Dry-to-touch is not full cure.

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48. Reassemble the cured case and captures

Parts: P01 · Floor; P02 · Roof; P03 · Left side; M01 · Roof mesh blank; ML · L vent mesh

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

1. Reassemble labeled parts in the accepted sequence using the existing holes. Restore every bearing contact and all fitted screen stacks.
2. Keep outside heads flush and inside locknuts/covers secure without crushing plywood or wires. Recheck actual cap spare depth and complete nylon engagement.
3. Check the roof sits on its intended solid bearings and still removes independently. No veneer or finish may bridge the removable seam.

Check before continuing: The cured shell retains its square, supported and serviceable dry-fit condition.

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49. Fit cushions, panes and removable beads

Parts: G1 · Door 1 OPTIX pane; N1FL · Door 1 F cushion L; N1RL · Door 1 R cushion L; N1S00 · Door 1 setting pad 0 layer 0; Q1L · Door 1 spacer L; B1L · Door 1 retaining bead L

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

1. Lay each supported door rear upward. Fit the plain front neoprene face strips and two setting-pad stacks, two 1/16 in (1.59 mm) layers at each bottom support position.
2. Set in the clean actual pane, retain the accepted 1/8 in (3.18 mm) perimeter allowance and add the separate rear solid strips. Fit labeled beads so they stop on their wood spacers.
3. Use the existing #6 stations with light, even contact. Check no bow, forced compression or rattling, and prove the supported pane can later be removed without cutting adhesive.

Check before continuing: Both cured glazing assemblies pass the recorded light-contact and expansion checks.

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50. Refit supported doors and check final gaps

Parts: H11_pin · 1798A21 removable pin reference; H12_pin · 1798A21 removable pin reference; H13_pin · 1798A21 removable pin reference; G1 · Door 1 OPTIX pane; G2 · Door 2 OPTIX pane

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

1. With helpers carrying each tall glazed leaf, refit the accepted hinges and pins. Support the leaf until every hinge is positively engaged according to received instructions.
2. Check at least 1/16 in (1.59 mm) finished gaps through the complete sweep, with the roof fitted. Test each swivel and flap independently before opening that door.
3. Repeat supported pin-removal and roof/pane service rehearsals after cure. Record any binding or frame change; do not shave through veneer as an unexplained repair.

Check before continuing: Both finished leaves secure, swing and remove with the accepted support and clearances.

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51. Install and verify both site restraints

Parts: RT · External rear restraint receiver

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

1. Place the empty finished enclosure on its assessed full-footprint support. Install both complete kits using the accepted site-specific bracket layout and manufacturer instructions.
2. Keep furniture brackets on solid RT, all components outside, and wall attachments in the assessed structural support. Insert and secure all supplied cable pins and retainers.
3. Have the loaded stability, attachment and maintenance release checked for this site. Record the result separately from digital validation; keep this hold open until completed.

Check before continuing: The actual support and two external restraint installations are accepted before use.

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52. Commission the optional fixture and containment

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

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

Before you begin: The maker’s dimensional wording is ambiguous; receive and measure. Geometric wood margin is not a thermal clearance or operating wattage recommendation.

1. The optional fixture is a receiving example, not a prescription. At the revised reference centre X = 10.1555 in (257.95 mm), Y = 11 in (279.4 mm), verify the actual rigid rim seats on both steel strips at all four contacts through the screen.
2. The proposed envelope is at most 6 in (152.4 mm) overall diameter with a 5 1/2 in (139.7 mm)–6 in (152.4 mm) rim and at most 2 lb assembled mass (0.91 kg). These are untested design limits, not confirmed product dimensions or a roof rating.
3. Keep the right roof heat-free. Follow actual equipment instructions, protect cords, use appropriate controls and measure temperatures/ventilation before animals. Check species-specific gaps and secure containment separately.

Check before continuing: Actual fixture fit, prototype load/thermal tests and animal-specific conditions are documented.

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53. Service screens, glazing and removable doors

Parts: P02 · Roof; G1 · Door 1 OPTIX pane; B1L · Door 1 retaining bead L; H13_pin · 1798A21 removable pin reference; RT · External rear restraint receiver

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

1. Disconnect and cool equipment, secure occupants elsewhere and empty the enclosure before service. Keep the case supported and restrained as the accepted maintenance plan requires.
2. Support a tall door before withdrawing any pin; use the received sequence and helpers, keeping all weight supported. On the bench, support its pane before removing beads and loose cushions.
3. Remove roof and side captures through their verified paths with retained parts labeled. To reach the upper back-ledger screws, first support the empty case under the accepted site plan, release the restraint cables and remove RT. Restore both restraints before service use.
4. Refit the accepted stacks and repeat all affected gap, fastener, bond, load and containment checks after repair.

Check before continuing: Maintenance leaves no loose pane, exposed tail, damaged edge or unverified replacement.

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54. Record each separate acceptance status

Parts: Accepted material samples and the named workshop setup

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

1. Record research, dimensions, calculations and digital validation against this exact versioned specification and model.
2. Record prototype construction, physical tests and qualified review only when performed, including actual measurements, equipment, date and reviewer. Leave unresolved fields open.
3. Keep the construction review packet and original source evidence. Record publication separately from all physical acceptance.

Check before continuing: The review packet separates research, digital validation, publication and remaining physical acceptance.

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