We first cut all the parts (per CNC File or Paper Template). NOW is a good opportunity to sand everything as required (much easier than after assembly). OK, we’ve got 30 minutes working time with the glue, let’s think of a plan:

I first applied glue along the mating edges of the wall panel, bottom panels, and the first/second dividers. 30-minute countdown ON!

I fitted the first and second dividers into the back wall (with glue):

I then flipped the wall panel and the dividers onto the bottom panel (with glue):

I applied glue to the remaining dividers and fitted them in place (it’s important to glue ALL mating surfaces for strength, but also to prevent squeaking):

I used a whole bunch of brad nails to secure the wall panel with the bottom panel and the dividers. The brad nails don’t play a structural role; they allow to precisely and instantly align the parts and hold them in place while the glue cures:

Some of the dividers expanded slightly and wouldn’t fit all the way to the bottom of the slot, but clamps solved the issue (hammering them in did NOT work!). With all the super tight tolerances it wasn’t exactly easy to fit together, but now that it’s assembled it’s never going apart! I let the glue do its thing for 24 hours (don’t stress the joints!).

I came back 24h later to add the top panel. To get a perfect alignment at the front (which is visible), I aligned the top panel and the divider (1) with one brad nail (glue was applied prior). Then, I worked my way along the edge (2 -> 3 -> 4 -> 5 -> 6):

(this photo was taken a bit later… ignore the other nails at this point!)

I then nailed the remaining of the top panel to the dividers. I used about 6 nails per divider:

I added clamps between the dividers, to ensure contact between the top and wall panels (the 1/4″ wall panels is too thin to accept nails):

The mating surfaces between the wall and top panel are very narrow; I was a bit worried it could unglue in the long run, so I added a bead of PL Premium 3X along the edge in the back:

I also added a bead of PL Premium 3X along the edge inside the cabinet (I used painter’s tape to get a clean line). PL Premium has peanut butter consistency and doesn’t drip down:

We routed the doors (per CNC or Paper plan) and installed the latch on each door:

We then installed the hinge’s clips to the back of the doors:

The Blum Aventos HK-S has two indexing pins to locate them precisely without trial and error:

Three screws per hinge (screws are included and are the correct length for 12mm thick plywood):

I couldn’t use screws where there are two adjacent hinges, so I used M4 x 60mm bolts and nuts:

All the hinges installed!

Install the brackets for the latches with #6 x 3/8″ screws:

To install the doors, simply clip them to the hinge arms. Easy! And easy to remove as well:

The shelves have about 1/8″ clearance all around and are fastened with these brackets. The “peg” is inserted into a 5mm diameter hole, and is screwed into the shelf (to prevent rattle on the road):

It’s in!

The aluminum channel, LED strip, and diffuser are cut to length and inserted into the 17.1mm wide x 6.5mm deep slot in the bottom panel:

I added a #4 x 3/4″ screw into each divider to secure the channel (I can add CA glue later if the channel sags between the dividers…):

There is a cutout on the rear divider to let the wires through: