Build the twin-door wooden enclosure

1. Plan the base and service space

Parts: Complete shell and its supporting furniture

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: No load rating, stacking approval or physical test is supplied.

1. Provide continuous, rigid, level support under the entire finished floor. Bare body is 48 in (1219.2 mm) wide × 24 in (609.6 mm) deep × 24 in (609.6 mm) high; maximum covered wood is 48.092 in (1221.54 mm) × 24.092 in (611.94 mm) × 24.092 in (611.94 mm), plus projecting hardware.
2. Reserve 21 in (533.4 mm) in front and the complete two-door swing sector, 4 in (101.6 mm) above each upper hinge pin, and room to lift and carry the roof. Plan helpers, a padded bench and the transport route.
3. Record actual shell, contents and equipment weights; have the supporting furniture, floor and stability assessed for that load. Keep the back and all ten solid supports in the design.

Check before continuing: Support, clear service paths and handling plan are recorded.

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2. Resolve material and product holds

Parts: H01–H07 and this revision’s shopping list

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: Do not treat a published digital plan as a tested physical enclosure.

1. Read H01–H07 before buying or making dependent cuts. Obtain supplier/qualified answers for hinge spacers, hasps, veneer balance, glazing, flush capture connections, finish exposure and complete support.
2. Choose one maple, white-oak or walnut veneer system. Confirm the exact backing, pressure-sensitive adhesive (PSA), sealer, balancing layer, application pressure, acclimation and required dwell.
3. Record actual models and supplier decisions. A photograph or matching nominal dimension is not an accepted substitution. Added layers or changed products require recalculation of dependent parts.

Check before continuing: All decisions needed for the next operation are recorded.

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3. Measure and label the received stock

Parts: Plywood, pine, acrylic, rubber, mesh and metal

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Measure plywood at corners and centre; reference gauge is 45/64 in (17.86 mm). Save labeled offcuts as gauges. Check full sheet size, grain, flatness, damage and voids at bearing/fastener locations.
2. Reference flat pine is 3/4 in (19.05 mm) thick and solid supports are 1 1/2 in (38.1 mm) square. Check actual acrylic, plain neoprene, welded crossings, steel, hinge leaves, screws, washers, nuts and covers.
3. Fill in the receiving worksheet. Use actual gauges and clamped opening measurements for mating parts; keep precise reference decimals rather than rounding a fit to a convenient tape fraction.

Check before continuing: Products, thicknesses, stock condition and actual usable sizes are recorded.

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4. Trial clearance holes, pilots and flush seats

Parts: Actual fasteners and matched wood offcuts

Tools / setup: Stopped drill, actual bits and countersink, caliper, clamp and backer

Before you begin: Clamp work; keep hands away from the rotating bit.

1. Clamp the stack on a backer. A clearance hole lets the screw pass freely through the first member; a smaller pilot guides its threads into the final receiver. Match the actual root after an offcut trial.
2. Reference #8: 11/64 in (4.37 mm) clearance and 7/64 in (2.78 mm) pine pilot. Reference #6: 9/64 in (3.57 mm) clearance and 3/32 in (2.38 mm) pilot. Hasp #10: 13/64 in (5.16 mm) clearance and 1/8 in (3.18 mm) pilot. Never use those wood pilots for through machine screws.
3. Use the matching 82-degree seat for flat heads, stopping when the actual head is flush without crushing wood. Set drill stops including the bit point; inspect buried tips and both faces. Do not enlarge purchased hinge/hasp countersinks.

Check before continuing: No splitting, stripping, crushed seat or exposed point.

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5. Make and trial the full hinge spacers

Parts: Four 1798A21 hinges and eight SP spacers

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: The custom spacer mounting is a supplier/qualified-review hold, not a rated hinge installation.

1. Cut eight 3 in (76.2 mm) × 1 1/16 in (26.99 mm) spacers from 1/8 in (3.18 mm) solid aluminium bar. Support and clamp metal for cutting/drilling; deburr every edge. Pair thicknesses must match and be at least 7/64 in (2.78 mm).
2. On full-height crossed-pine offcuts reproduce the 3/16 in (4.76 mm) bare hinge gap and coplanar front faces. Put the entire solid spacer behind each hinge leaf, with no veneer or adhesive underneath.
3. Transfer the actual three holes per leaf. Trial dedicated #8 × 1 1/2 in (38.1 mm) W150 heads and stopped pilots. Reference tip depth is 1.295 in (32.89 mm) into the wood face; 0.545 in (13.84 mm) enters the final rear layer after clearance through the front layer. Obtain mounting/capacity acceptance before proceeding.

Check before continuing: Both leaves bear fully, axes align, heads seat and the accepted fixing stack is recorded.

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6. Prove finished swing and roof-on pin removal

Parts: Accepted hinge trial, finished edge samples and complete pins

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Apply the accepted veneer and coating to the trial and fully cure. Total cured added layer is reference 0.0305 in (0.77 mm), maximum 0.046 in (1.17 mm) per face. Require at least 1/16 in (1.59 mm) finished closed gap and free 100-degree door movement.
2. Keep the source absolute hinge centres, now 2 7/16 in (61.91 mm) from the trimmed top/bottom wood ends. The 1/8 in (3.18 mm) stand-off keeps pins in front of the veneered roof edge. Test the real maximum pin/head envelope, not just its shaft.
3. With the door fully supported, pull upper pin first and lower second. Move the supported leaf clear without twisting. Refit lower pin then upper and repeat the complete swing and latch fit.

Check before continuing: Actual finished trial moves and removes with the roof present and no contact.

Required wait: Supplier-prescribed veneer dwell and full coating cure before the finished trial.

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7. Trial both keyless hasps

Parts: Two N305-979 hasps and fourteen HASP-SCREW fixings

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Use matching crossed-pine offcuts and the finished latch gap. Fixed hinged base goes on the centre post; square swivel plate goes on its own door. Only the flap crosses the joint.
2. Trace the complete received plates. The revised moving plate retains only about 0.02 in (0.51 mm) wood beyond its edge, so reject any overhang. Keep hole centres at least 1/4 in (6.35 mm) from wood edges and all tips at least 1/16 in (1.59 mm) short of the far face.
3. Transfer one hole in each plate, loosely fit the specified #10 × 5/8 in (15.88 mm) screws, then try the tab and flap. Transfer all seven only after free hand operation without sideways pull. Do not alter metal slots or cover unsupported plate edges with veneer.

Check before continuing: Each hasp independently secures/releases its own door and all plate/fastener support is accepted.

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8. Trial the flush screen connection

Parts: BOLT, WASH, LOCK, CAP and actual capture offcuts

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: No torque, clamp-force or connection capacity is established. Prove the changed bearing with qualified review.

1. Use one 1/4-20 flat-head screw, one inside washer, one nylon locknut and a separate closed tip cover. Make a 9/32 in (7.14 mm) clearance hole through the actual stack; trial the exterior 82-degree countersink until the head is flush with bare plywood.
2. The reference head diameter is 0.477 in (12.12 mm); published head height 0.153 in (3.89 mm) is a receiving envelope, not a drilling depth. Preserve intact plywood under the seat. Veneer needs an accessible 1/2 in (12.7 mm) head-service opening.
3. Fit the actual stack, mark the inside locknut face, and reserve 1/8 in (3.18 mm) – 7/32 in (5.56 mm) of tail beyond it. Require two complete threads after at most 1/64 in (0.4 mm) chamfer and at least 1/32 in (0.79 mm) of unused blind cap depth. Reject a supplied length that cannot satisfy both limits.

Check before continuing: Actual seat, stack, full threads and cover clearances are measured.

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9. Prove two-wrench and screen-pocket access

Parts: Received screen, capture trial and service tools

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Reference wire diameter is 0.041 in (1.04 mm) and clear aperture 1/2 in (12.7 mm). Two crossing wires occupy about 0.082 in (2.08 mm); measure the actual welded peaks. Maximum accepted crossing is 3/32 in (2.38 mm) inside a 1/8 in (3.18 mm) pocket, with finish allowance.
2. Recess the back of each capture, retaining continuous outer bearing lands. Clamp a wire coupon without crushing it, then transfer the bolt through an open cell. Never sever a perimeter weld to clear a screw.
3. Hold the locknut with a thin 7/16 in (11.11 mm) wrench while turning its cover with another. Prove the actual tool envelope, reference no more than 3/4 in (19.05 mm) outside diameter, at side/roof stations. Use direct Phillips #3 access outside; the nose passing the 1/2 in (12.7 mm) veneer access hole must be no more than 3/8 in (9.53 mm) across. Keep a wider bit holder clear of the veneer.

Check before continuing: Flat bearing, protected wire ends, free tool approach and removable cover are demonstrated.

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10. Prepare the veneer bond and balance sample

Parts: Selected veneer, substrate, sealer and coating

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Ask the veneer supplier to approve the complete substrate/sealer/backing/adhesive/topcoat combination and the required balance on opposite faces. Obtain its acclimation, pressing and dwell instructions in writing.
2. Use a full representative panel and edge/reveal samples. Include a service seam, a bare hinge footprint and a fastener access opening. Apply using the prescribed scraper/pressure; do not substitute an unapproved roller.
3. Measure cured thickness and inspect bond, flatness and edge lifting through the intended indoor cycle. Maximum added stack is 0.046 in (1.17 mm). Additional balancing material changes the construction and must be incorporated before final cutting.

Check before continuing: Supplier acceptance and a satisfactory cured sample are recorded.

Required wait: The selected supplier’s acclimation, adhesive dwell and coating cure; no invented universal dwell.

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11. Cut and identify the five plywood panels

Parts: P01, P02, P03L, P03R and P04

Tools / setup: Supported saw setup, square, tape, marking knife and helpers

1. Follow the two-sheet grain-fixed layout with 1/8 in (3.18 mm) edge trim and 1/8 in (3.18 mm) saw kerf. Rough lengths include 1/8 in (3.18 mm) for final fitting. Support the full sheet and offcut during every guided cut.
2. Reference floor and roof finish 48 in (1219.2 mm) × 24 in (609.6 mm). Side and back height is 24 in (609.6 mm) minus twice actual plywood thickness; reference 22 19/32 in (573.88 mm). Back width is 48 in (1219.2 mm) minus twice thickness; reference 46 19/32 in (1183.48 mm).
3. Mark the inside face, front edge and lower end on every part. Keep the left and right walls distinct. Dry-fit the back between sides before final trimming; compare diagonals without forcing.

Check before continuing: Panel dimensions close the actual-thickness chain and labels remain readable.

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12. Cut the side ventilation openings

Parts: P03L and P03R

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Place each wall inside-up on sacrificial backing. Mark its front and bottom datums. The opening runs 7 in (177.8 mm) – 15 in (381 mm) from the front and 4 in (101.6 mm) – 6 in (152.4 mm) above the panel bottom, giving 8 in (203.2 mm) × 2 in (50.8 mm).
2. Clamp wall and waste securely. Drill a starter hole inside waste, then use a guided jigsaw/router with a supported template; do not run into cleat or bolt lands.
3. Square and smooth cut edges without rounding the measuring surfaces. Check both openings against the same gauge. These are raw openings; reveal veneer later reduces each dimension by twice its cured thickness.

Check before continuing: Matched openings leave intact support, frame and capture zones.

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13. Cut both roof openings

Parts: P02 removable roof

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. From the roof’s left/front datums, mark rectangles X 4 in (101.6 mm) – 22 in (558.8 mm) and 26 in (660.4 mm) – 44 in (1117.6 mm); both run Y 6 in (152.4 mm) – 18 in (457.2 mm). Each raw opening is 18 in (457.2 mm) × 12 in (304.8 mm).
2. Support the roof and both wastes; make guided cuts with the safe starter/template method. Preserve the solid 4 in (101.6 mm) centre web above the roof rib and the entire outside rim.
3. The revised steel seats belong in the inside capture battens. Do not make the old roof-top steel pockets. Smooth the openings and retain their exact datum edges for reveal veneer.

Check before continuing: Openings and web match the roof drawing; roof perimeter lies flat.

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14. Cut the ten solid supports

Parts: CLB, CRB, CLU, CRU, CLT, CRT, CB, CT, CC and CR

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Use the three solid 1 1/2 in (38.1 mm) square-stock layouts. Keep square end cuts and label each support by its actual part ID.
2. Reference side horizontal supports and centre roof rib are 21 51/64 in (553.64 mm) long; rear uprights 19 19/32 in (497.68 mm); rear cross supports 43 19/32 in (1107.28 mm); centre column 21 3/32 in (535.78 mm). Confirm the actual-stock worksheet before final crosscuts.
3. Dry-fit side supports between front frame and inside back; use real plywood offcuts as spacers. Keep full bearing faces, not point contact or gaps filled with glue.

Check before continuing: All ten supports fit their own measured load path; no split or defective bearing stock.

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15. Machine the rear roof half-lap

Parts: CT rear ledger and CR centre rib

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. A half-lap removes half the thickness from each overlapping member. On CT, locate the centred 1 1/2 in (38.1 mm) width of CR, reference X 23 1/4 in (590.55 mm) – 24 3/4 in (628.65 mm) in assembly coordinates.
2. Remove 3/4 in (19.05 mm) from the top of CT across its full 1 1/2 in (38.1 mm) depth. Remove the matching 3/4 in (19.05 mm) from the bottom of CR at its rear 1 1/2 in (38.1 mm) length. Clamp with a template and backer; use a guided router or safe supported saw/chisel setup.
3. Dry-fit the two shoulders. Their combined height remains 1 1/2 in (38.1 mm) and the rib top aligns with the surrounding roof ledgers. Keep the actual shoulder registration for later drilling.

Check before continuing: Full shoulder bearing, correct top height and no rocking or split short grain.

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16. Plane wide blanks for caps, spacers and stops

Parts: Pine boards allocated by final thickness

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Keep each board wide and long during thickness planing. Required reference sections are 3/4 in (19.05 mm) frame/capture stock, 3/8 in (9.53 mm) stops, 11/32 in (8.73 mm) glazing spacers and 1/4 in (6.35 mm) caps.
2. Use the machine’s minimum thickness/length, guarded feed and approved carrier where needed; commission a milling service if your tooling cannot safely hold the stock.
3. Only after planing, rip the scheduled widths with guards, riving knife and push aids. Crosscut supported narrow pieces using a safe fixture; never hold a short strip by hand at a blade.

Check before continuing: Thicknesses and safe feeding conditions are verified before making narrow parts.

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17. Cut the crossed front-frame pieces

Parts: F0 and F1 members

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Use the cut schedule for ten pieces. Front layer has full-height outer stiles; rear layer has full-width top/bottom rails. Their crossing grain bridges the butt joints.
2. Keep the 3 1/2 in (88.9 mm) lower rail and 2 1/2 in (63.5 mm) upper/outer/centre members. Reference opening height is 16 19/32 in (421.48 mm); each opening width is 19 35/64 in (496.49 mm).
3. Dry-lay both layers on the bench, front faces down, with outside reference marks aligned. Check both openings and both frame diagonals before drilling.

Check before continuing: The two openings match and every butt joint is bridged by the other layer.

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18. Glue and fasten the fixed frame

Parts: F0/F1 and 36 W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Trace the opposite-layer receivers and transfer the exact 36 stations from the frame drawing. Separate layers to enlarge only the first layer for shank clearance; drill stopped pilots in the receiving layer.
2. Apply Titebond III evenly to clean bare mating faces; use straight cauls and clamps across both width and height. Work within the received label’s assembly time.
3. Drive the 36 #8 × 1 1/4 in (31.75 mm) screws flush without stripping, keeping the frame flat and square. Remove squeeze-out without flooding the joints.

Check before continuing: Flat frame, equal diagonals and fully seated crossed layers.

Required wait: At least 24 hours unstressed before machining; actual temperature/humidity and current glue instructions control.

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19. Cut and label both door-frame layers

Parts: DL0/DL1 and DR0/DR1

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Cut the two mirrored crossed-layer frames from their own schedule. Outer hinge stiles are DL0H/DL1H and DR0J/DR1J. The broader inner latch stiles face the centre post: DL0J/DL1J and DR0H/DR1H. Keep these original part IDs with their own dimensions.
2. Preserve the source viewing openings. Only final outside perimeters are trimmed for veneer: 1/16 in (1.59 mm) from each hinge edge and top/bottom, 1/32 in (0.79 mm) from each latch edge.
3. The resulting reference wood leaf is 19 13/64 in (487.76 mm) × 16 7/32 in (411.96 mm). Keep left/right and bottom marks visible when turning over; do not swap the different hinge/latch stile widths.

Check before continuing: Mirrored layers preserve the original pane openings and the intended perimeter allowance.

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20. Glue and fasten each door frame

Parts: Both crossed door frames; 32 W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Dry-clamp each frame on a flat padded bench. Use its 16 exact rear-face stations: eight stile and eight rail connections. Compare both front and rear hardware zones before drilling.
2. Clearance-drill the first layer and make stopped pilots in the receiver. Apply glue to bare faces, clamp with straight cauls and drive 16 #8 × 1 1/4 in (31.75 mm) screws per door.
3. Check diagonals, viewing-opening shape and flatness while glue remains workable. Leave pane, pads, caps and hardware off during curing.

Check before continuing: Both frames stay square and flat with fully buried screw tips.

Required wait: At least 24 hours unstressed before subsequent machining, per actual label/conditions.

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21. Fit the perimeter and five-degree rear latch bevel

Parts: Both cured door frames and fixed openings

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Shim each bare door in its own square opening. Target 3/16 in (4.76 mm) hinge/top/bottom gaps and 5/32 in (3.97 mm) latch gap. Record final wood sizes; never consume the broad latch plate’s bearing area to force a fit.
2. On the latch edge only, mark a 5-degree bevel from the front arris toward the rear. The front outline stays at its fitted dimension; the back is relieved, removing about 0.13123 in (3.33 mm) across 1 1/2 in (38.1 mm) thickness.
3. Clamp in a supported edge-working fixture and plane/router to the line. Check the matching veneer edge will follow this real slope; preserve the viewing opening and glazing spacer lands.

Check before continuing: Gaps and bevel agree with the drawing, with enough supported wood for every hasp screw.

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22. Cut the two floating acrylic panes

Parts: AL and AR

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: Wear eye protection and use the manufacturer’s safe cutting method; avoid incompatible cleaners.

1. Use the current OPTIX fabrication instructions, sharp compatible tooling and full-sheet support. Reference each pane is 16 19/64 in (413.94 mm) × 13 19/32 in (345.28 mm) × 0.22 in (5.59 mm).
2. Protect surfaces while cutting; smooth edges without heat damage. Do not drill the panes for wood screws. Match dimensions to the accepted supplier/actual-pocket movement calculation.
3. Trial the 3/8 in (9.53 mm) bearing overlap around each raw viewing opening and 1/8 in (3.18 mm) edge clearance to each spacer. Final coating and thermal/moisture movement remain part of the receiving check.

Check before continuing: Both panes lie flat, are undamaged and enter their pockets freely.

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23. Fit the pane spacers, pads and removable caps

Parts: G/K strips, trapped neoprene and both panes

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Plane the wide spacer stock to the accepted actual pane plus two pad layers. Reference spacer height is 11/32 in (8.73 mm); the front pad is 1/16 in (1.59 mm) and the rear reference contact is about 0.06125 in (1.56 mm).
2. Cut plain neoprene strips to the schedule; butt corners without doubled layers. The compound must be accepted for acrylic/contact/temperature use and remain mechanically trapped.
3. Seat caps fully on spacers with light even pane contact, preserving 1/4 in (6.35 mm) cap overlap and free edge space. Reject bow, rattle or wedging; never use screw torque to flatten a wrong spacer stack.

Check before continuing: Cured trial proves floating edge movement and even non-distorting retention.

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24. Cut and protect the four mesh blanks

Parts: ML, MR, MTL and MTR

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Wear eye protection and protect hands from cut wire. Cut two side blanks 9 1/2 in (241.3 mm) × 3 1/2 in (88.9 mm) and two roof blanks 19 1/2 in (495.3 mm) × 13 1/2 in (342.9 mm) from the scheduled roll.
2. Keep the actual cut-wire envelope inside those dimensions and retain intact perimeter welds. Deburr or reject sharp broken ends and tag each blank.
3. The nominal clear aperture is 1/2 in (12.7 mm), with 0.041 in (1.04 mm) reference round wire and 0.541 in (13.74 mm) pitch. Measure actual wire and crossings; this mesh is not universally suitable for hatchlings, feeders or every animal.

Check before continuing: All cut ends will be buried under their matching capture, with no damaged welds.

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25. Route the side capture pockets

Parts: VLB/VLT/VLF/VLA and mirrored right pieces

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Use a clamped full-length carrier/template for the eight capture strips. Their panel-facing backs need 1/8 in (3.18 mm)-deep pockets following the side mesh blank, plus 0.006 in (0.15 mm) relief at the perimeter.
2. The outer pocket envelope is Y 6.244 in (158.6 mm) – 15.756 in (400.2 mm), Z 3.947125 in (100.26 mm) – 7.459125 in (189.46 mm) in the reference assembly. Retain 0.244 in (6.2 mm) continuous outer bearing lands; pocket intersections differ between long and end strips.
3. Trial actual cloth plus cured finish inside the pocket. Capture wood must bear flat on the plywood, without resting on welds. Use the individual part drawing to transfer global marks to each labeled face.

Check before continuing: Pockets retain full outer lands, protected wire ends and room for the measured crossing.

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26. Transfer side screen fastener stations

Parts: Side mesh/captures and twenty BOLT sets

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Centre each screen over its 8 in (203.2 mm) × 2 in (50.8 mm) opening, then clamp the routed capture with outer lands against the wall. Keep the pocket and screen orientation marked.
2. Use the exact revised 0.541 in (13.74 mm) open-cell stations. The original 3 in (76.2 mm)-spacing marks are superseded; transfer actual received mesh while keeping fasteners on supported capture zones and away from wood screws.
3. Drill 9/32 in (7.14 mm) clearance through the matched clamped stack, with no wire cut at a bolt. Trial exterior 82-degree seats; keep parts registered and remove all sharp chips before reassembly.

Check before continuing: Ten through connections per side, clear cells and full exterior head/inside washer bearing.

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27. Prepare and fasten the floor supports

Parts: P01, CLB, CRB and CB; twenty W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Support the floor on a flat padded bench. Use a back-panel offcut to locate CB between the side cleats at the future inside back face. Trace all three receiver centre lines.
2. Transfer five stations per side cleat and ten along CB from their exact schedules. Clamp and mark locating holes, then separate to clearance-drill the floor and make stopped pine pilots.
3. Refit to registration marks and fasten from below with twenty #8 × 1 1/4 in (31.75 mm) flush screws. Helpers and padded risers must allow drilling without reaching blindly under unsupported panels.

Check before continuing: Floor remains flat, all three supports bear fully and no screw tip emerges.

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28. Raise and brace both walls

Parts: P03L/P03R, CLU/CRU, CLT/CRT; thirty W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Set walls on the floor with front marks aligned. Brace each square while helpers hold it; do not depend on a few partly driven screws for temporary stability.
2. Fit rear uprights between floor cleats and top ledgers. Use the real back gauge at the rear; all upper support faces must align below the roof.
3. Transfer five stations into each lower cleat, upper ledger and rear upright per wall. Clearance-drill the panel only, pilot pine with stops, and fit 15 flush #8 × 1 1/4 in (31.75 mm) screws per wall. Keep braces until the fixed front is secure.

Check before continuing: Walls stay square and supports seat fully, with protected tips and intact vent zones.

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29. Fit and fasten the back

Parts: P04, CB, CT, CLU and CRU; twenty-eight W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Fit the back between walls. Set CT so its top is flush with side-ledger tops. Lay an actual roof offcut above it: its upper face must reach the 24 in (609.6 mm) bare body height.
2. Trace receivers, register, remove and clearance-drill the back; clamp again to transfer stopped pilots. Use ten fasteners into each cross support and four into each rear upright.
3. Drive all 28 #8 × 1 1/4 in (31.75 mm) screws flush while checking equal shell diagonals. Do not lower CT by another plywood thickness or use screws to close an unseated joint.

Check before continuing: Back and support tops align, shell stays square and every receiver bears fully.

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30. Attach the crossed front frame

Parts: Cured fixed frame and nineteen W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Lay the shell on its padded back with helpers and stable blocks. Fit the complete frame between walls, over the floor, with its front face flush.
2. Transfer five wall-to-frame stations per side and nine floor-to-sill stations. The reference side entry is 0.55 in (13.97 mm) behind the front; floor entry is 0.65 in (16.51 mm) back. Use exact traced receiver locations, not rounded tape approximations.
3. Clearance-drill panels and pilot the receiver. Fit the 19 #8 × 1 1/4 in (31.75 mm) screws, checking both openings remain equal before removing temporary braces.

Check before continuing: Frame is fully seated and shell diagonals/openings agree.

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31. Install the centre bearing and roof rib

Parts: CC, CR, CT; five W200 and one W125 screw

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Place CC on the floor, centred behind the fixed centre stile. Clamp its full face to the frame. Four #8 × 2 in (50.8 mm) front screws pass through both frame layers into CC.
2. Seat CR on CC at the front and in CT’s rear half-lap. Roof support tops must align. Transfer the front and rear rib stations on its width centre line, 3/4 in (19.05 mm) from each end.
3. Use one #8 × 2 in (50.8 mm) screw at the front bearing and one #8 × 1 1/4 in (31.75 mm) at the rear lap. Preserve full lap shoulders and avoid crossing nearby screws.

Check before continuing: Rib top is level with ledgers and lies below the solid roof web; no unsupported bearing.

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32. Fit the eight recessed door stops

Parts: STL/STR stops and thirty-six W100 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. With the shell supported, place each door front flush using shims. Set stops behind the leaf without pushing it out of plane; preserve room for glazing caps.
2. For each vertical stop, mark the screw line 3/16 in (4.76 mm) from its outer long edge backed by fixed frame; four stations with 1 in (25.4 mm) end setbacks. Horizontal stops use 1/4 in (6.35 mm) from the backed outer edge and five stations with 1 in (25.4 mm) end setbacks.
3. Remove doors for access, transfer receivers and fit 36 #6 × 1 in (25.4 mm) screws from the rear. Keep bores out of gaps and leave every tip buried.

Check before continuing: Stops establish the closed plane without binding doors or caps.

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33. Route the inside roof screen retainers

Parts: Eight RTL/RTR strips

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Place the labelled retainers underside-up on a safe clamped carrier. Their top faces meet the roof underside; the retainers are now inside the enclosure.
2. Route the mesh pockets 1/8 in (3.18 mm) deep, retaining 0.244 in (6.2 mm) outside lands. Left pocket X 3.244 in (82.4 mm) – 22.756 in (578 mm); right X 25.244 in (641.2 mm) – 44.756 in (1136.8 mm); both Y 5.244 in (133.2 mm) – 18.756 in (476.4 mm). Use part-relative drawings for each strip.
3. Dry-fit with screens beneath the roof. Check retainers clear the side ledgers, centre rib and rear support. Do not add the old raised roof-top frames.

Check before continuing: Flat inside bearing and protected screen edges with no interference at roof supports.

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34. Machine the four steel bearing seats

Parts: RTLF/RTLA and LB1/LB2

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Cut two 14 in (355.6 mm) steel strips from the 1 in (25.4 mm) × 1/8 in (3.18 mm) bar and deburr all edges. Revised centre lines are X 11.074 in (281.28 mm) and 14.861 in (377.47 mm), measured from roof left.
2. In the inside front/rear left-screen retainers, cut 1 in (25.4 mm)-wide seats to match actual strips. Reference steel underside is Z 23.083875 in (586.33 mm), so its top sits 0.088 in (2.24 mm) below the roof underside and supports the mesh.
3. Seat both ends fully. Actual steel, weld crossings and finish control pocket depth; retain sound wood beneath each seat. Do not claim a fixture load rating from this dimensional fit.

Check before continuing: All four bearing surfaces are level, solid and correctly placed under the screen.

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35. Drill roof screen and steel connections

Parts: Roof captures, screens, strips and thirty-six BOLT sets

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Clamp the complete detached roof stack on a padded bench. Use the revised open-cell stations: 18 connections for each screen, including four through the steel ends.
2. At each steel centre line, reference Y stations are 5 1/2 in (139.7 mm) and 18.484 in (469.49 mm). Transfer the four holes through the clamped stack; remove steel to drill/deburr 9/32 in (7.14 mm) clearance on a backer.
3. Drill matched roof/capture clearance, then trial all exterior 82-degree head seats. Reassemble to registration marks and confirm outer lands bear without crushed wire.

Check before continuing: Exactly 36 accessible through connections; all four steel ends captured without extra or missing bolts.

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36. Fit each through screw and protected tail

Parts: All 56 BOLT/WASH/LOCK/CAP sets

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: Do not cut screws on the enclosure or use an impact driver.

1. Reference overall screw length is 2 in (50.8 mm) including the flat head; reference wood grip is 1 29/64 in (36.91 mm). Measure each real finished stack instead of trimming all screws to the same length.
2. Assemble one inside washer and nylon locknut, then mark the permitted 1/8 in (3.18 mm) – 7/32 in (5.56 mm) tail. If shortening is required, remove the screw, clamp it in a vise, cut and file no more than 1/64 in (0.4 mm) chamfer. Apply an accepted compatible corrosion treatment to cut steel.
3. Refit with at least two complete threads beyond the insert and at least 1/32 in (0.79 mm) unused blind-cover depth. Hold locknut stationary while snugging cover with a second wrench. No outside washer and no proud head under veneer.

Check before continuing: Every joint clamps soundly without cap bottoming, crushed wood/wire or sharp reachable tails.

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37. Transfer the removable roof fixings

Parts: P02, side/rear ledgers and twenty W125 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Rest the assembled roof on all ledgers and the centre rib. Match outer edges without forcing; remove and correct any bearing that makes it rock.
2. Trace ledger centre lines on the roof underside. Transfer five fasteners to each side ledger and ten to CT, using the exact reference schedule and registered actual receivers.
3. Clearance-drill roof and make stopped pilots in ledgers. Fit twenty #8 × 1 1/4 in (31.75 mm) screws flush. Confirm every head remains accessible through its veneer service opening and that the roof lifts off after removal.

Check before continuing: Roof seats flat, removes as one supported assembly and retains all screens/steel during lifting.

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38. Transfer and install the four hinges

Parts: Four accepted hinges, eight spacers and twenty-four W150 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Put shell on its padded back. Block each door front flush, shim the revised bare gaps, and align both pins with a straightedge over its hinge gap.
2. Retain reference absolute hinge centres Z 6 53/64 in (173.43 mm) and 18 11/64 in (461.57 mm); these are now 2 7/16 in (61.91 mm) from trimmed wood ends. Transfer received holes from the accepted trial, checking all existing rear lamination fixings.
3. Keep full-leaf spacer/wood support and at least 3/8 in (9.53 mm) hole-centre distance from receiver edges and 1/4 in (6.35 mm) plan clearance from existing screws. Fit 24 dedicated #8 × 1 1/2 in (38.1 mm) screws with accepted stopped pilots; record actual shifts and recheck the entire sweep.

Check before continuing: Aligned pins, full bearing, accepted engagement, free movement and supported removal.

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39. Fit the two hasps to their own doors

Parts: Two hasps and fourteen HASP-SCREW fixings

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Reproduce the accepted offcut mounting at the finished gap. The two fixed bases mount at different heights on the centre post; each flap points toward its own leaf.
2. The revised reference left assembly shifts 1/32 in (0.79 mm) left and right assembly 1/32 in (0.79 mm) right with the trimmed latch edges. Actual complete hardware transfer governs; never drill directly from a render.
3. Fit one fixed-base and one swivel-plate screw loosely, test operation, then transfer and install all seven screws per hasp. Hand-turn tab, open flap fully, then open door; close in reverse order.

Check before continuing: Both hasps secure independently without a key or sideways pull, with every plate fully supported.

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40. Drill and dry-fit removable glazing caps

Parts: G/K strips, both panes/pads and forty W100 screws

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Remove panes before drilling. For each long cap mark 1/4 in (6.35 mm) from its outer edge away from the pane; five stations with 1 1/8 in (28.58 mm) end setbacks. Short caps use the same outer offset and five stations with 1/4 in (6.35 mm) end setbacks.
2. Clamp cap and spacer on the door; transfer receivers, then clearance-drill both cap and spacer and pilot only the door. Inspect the entire path outside the pane pocket.
3. Refit pads/panes and forty #6 × 1 in (25.4 mm) screws, tightening lightly until caps bear on spacers. Recheck movement space, even contact, no rattle and no acrylic bow.

Check before continuing: Both panes remain floating, protected and removable with intact screw lands.

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41. Rehearse door, pane and roof removal

Parts: Complete dry assembly

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: Secure the animal elsewhere and empty the enclosure for any later service.

1. Release each swivel and flap. Support its full door, withdraw upper pin then lower, and move clear without prying or carrying by acrylic. Rehang lower pin then upper.
2. On the detached door, front down on a padded bench, remove all cap screws and lift the four caps rearwards. Lift off the four rear pads, then lift the supported pane rearwards. Keep pads and caps labelled; refit without compressing a wrong stack.
3. Remove cooled/disconnected equipment and all twenty roof-to-ledger screws; lift the whole roof with helpers. On the bench rehearse screen/steel service using two inside wrenches. Restore and repeat every closure check.

Check before continuing: All maintenance paths work with actual hands, tools and supported parts.

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42. Disassemble and prepare for veneer

Parts: All wood, labelled hardware and accepted finish sample

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Mark every removable assembly and remove panes, pads, screens and hardware. Keep matched screws and registration marks together; photograph the dry-fit record.
2. Prepare clean, dry, sound surfaces using the accepted veneer supplier instructions. Preserve glue faces and bare metal-bearing seats; do not sand away a functional datum. Before bonding, complete any substrate sealer and balancing treatment required by the supplier-approved sample, including its prescribed cure and sanding. Record the actual products, sequence and added thickness; H03 remains open until this system is accepted.
3. Use the veneer layout to rough-cut labelled pieces with grain along their stated length. Keep roof/front rails running across the width so grain and edge geometry read consistently.

Check before continuing: All surfaces, seams and service seats match the accepted trial before bonding.

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43. Apply edge bands and opening reveals

Parts: All V edge/reveal pieces

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Band exterior plywood edges, door perimeters and side/roof/viewing reveals according to the part schedule. The latch band follows the real 5-degree bevel.
2. Apply prescribed pressure on fully supported surfaces, then trim cleanly with sharp tools and a backing block. Protect thin veneer from splitting or sanding through.
3. Keep every removable joint separate. Do not bridge door gaps, roof seams, glazing pockets, hardware footprints or bolt-service seats. Check the total cured thickness before covering faces.

Check before continuing: No raw exterior plywood edge remains; all movement and service joints stay open.

Required wait: Supplier-specified bond dwell before trimming or loading the edge.

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44. Veneer the roof, body and door faces

Parts: All V face pieces and selected species

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Apply the large faces after their edge bands so face veneer covers band ends. Include roof, floor underside, side/back faces, fixed front and both doors.
2. Use the supplier-approved pressure method on flat support. Keep grain direction, labels and service seams consistent; do not stretch or displace geometry to imitate grain.
3. Trim bare metal bearing footprints to the actual accepted hardware. Leave all specified head-access openings clear, including 1/2 in (12.7 mm) openings at through screws. Check flatness, bond and every finished gap.

Check before continuing: Exterior coverage is uniform, seams remain serviceable, and no added layer binds a door.

Required wait: Complete accepted adhesive dwell and sample acceptance before coating/reassembly.

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45. Apply the selected polyurethane system

Parts: Prepared wood and accepted veneer/sealer combination

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: Ventilate and follow actual product/tool protection instructions.

1. Follow the received Varathane Triple Thick label and accepted sample. Sand as specified, reference 120 through 220 grit, remove dust and use a synthetic brush along grain. Stir; do not shake.
2. Current reference application range is 60–90°F (15.6–32.2°C), below 85% relative humidity. One uniform coat is specified, nominal 9-mil wet and 3-mil dry film; do not substitute a generic three-coat recipe.
3. Record conditions, batch and final coat/repair time. Keep hardware/glue seats as accepted. Manufacturer floor exclusion, cleaning, heat and animal-contact suitability remain separate H06/H07 prerequisites.

Check before continuing: Uniform film with all specified edges/penetrations treated and no blocked service holes.

Required wait: Full cure at least 7 days at 70°F (21°C)/50% RH; adverse conditions need longer. Dry touch, no odour and 48-hour light use are not full cure.

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46. Reassemble the fully cured enclosure

Parts: All labelled parts and accepted hardware

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Refit screens, steel, washers, locknuts and closed covers. Recalculate each finished bolt stack, including coating, and repeat flush-seat/tail/cap checks.
2. Refit hinges/spacers and hasps to their bare bearing footprints; install both supported doors and then floating glazing with accepted pads/spacers/caps.
3. Check at least 1/16 in (1.59 mm) finished gap at every door edge, complete 100-degree swing and both latches. Recheck roof removal, pin extraction, sharp-edge protection, bond and flatness.

Check before continuing: No binding, unsupported hardware, exposed tips, loose screens or hidden raw exterior edge.

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47. Evaluate the optional fixture provision

Parts: Two inside steel strips and actual external fixture

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

Before you begin: No roof storage, suspended load, universal thermal clearance or rated fixture capacity.

1. This is only a provision for one external screen-top fixture over the left opening. Source example is Fluker Mini Sun Dome 27004; actual rigid rim 5 1/2 in (139.7 mm) – 6 in (152.4 mm), housing no more than 6 in (152.4 mm) across, proposed assembled weight no more than 2 lb (0.91 kg).
2. The revised rim support is lower inside the roof opening. Physically confirm four stable rim contacts over both steel strips, full housing clearance from roof/reveal veneer, and accepted load/thermal behaviour. Do not rest equipment elsewhere on unsupported cloth.
3. Follow fixture/bulb instructions and use an appropriate controller. The 100 W electrical maximum is not a recommended operating wattage. Qualified support and heat review, actual temperatures and animal-specific equipment decisions remain required.

Check before continuing: Actual fixture fit, support and heat checks are accepted before use; otherwise leave the provision unused.

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48. Commission containment and indoor conditions

Parts: Finished shell, actual animal and selected equipment plan

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Review every screen aperture, door gap, removable joint and cable path for the selected animal’s size and behaviour. A 1/2 in (12.7 mm) mesh aperture is not a universal containment choice.
2. Keep dry substrate no more than 2 in (50.8 mm) above the finished floor and maintain the low inlet path. Gross opening area and wire open fraction do not establish airflow, humidity or temperature suitability.
3. Measure operating conditions and surface temperatures under the actual room/equipment arrangement, with appropriate shade and gradients. Keep animals out until finish, containment, support and equipment prerequisites are satisfied.

Check before continuing: Separate animal/environment and equipment acceptance is recorded; missing evidence remains open.

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49. Record acceptance and future service checks

Parts: Receiving worksheet and maintenance record

Tools / setup: Tape, square, caliper, pencil, clamps and the tools named below

1. Keep this revision, actual material measurements, transferred hardware marks, cure times, supplier decisions and completed test results together. Leave unperformed prototype, physical and qualified-review fields blank.
2. Before later service, secure the animal elsewhere, empty the shell and disconnect/cool equipment. Use the supported removal order; brush/vacuum screens and use only accepted cleaners.
3. Inspect veneer edges, coating, welds, captured mesh ends, screws, locknuts/covers, hinges and steel after service or configuration changes. Replace damaged parts and repeat fitted/commissioning checks before reuse.

Check before continuing: Records clearly separate digital planning, actual fabrication, testing, qualified approval and publication.

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