I'm gong to have to make one of those circular saw guides for myself. It will be faster than my method.
In the last posting I had finished gluing the 19/32 plywood pieces together to make the new End Pieces. I need to round off the top front corner of each End Piece. To do this I first must draw an arc. There are a bunch of ways to do this. I picked the easiest.
Find the biggest round thing you have. In my case that would be a garbage can.
Place the garbage can on the End Piece and line it up with the edge. Then trace out your arc.
Use the arc as a guide for the saber saw to trim off the edge.
To smooth out the arc I clamped the End Piece to my workbench using one of the vices.
Then used a belt sander to do the smoothing.
Did the same for both End Pieces. That finished work on the End Pieces for the time being. Start to work on both the Seat and Back Platforms.
When I routed the boards that make up the frame of the Platforms I left the rounded corner.
Time to fix that with hammer, wood chisel and two paws. Use the hammer and chisel to square off the inside corner.
From 19/32 plywood cut two panels that fit into the routed out sections on the Back Platform.
Once I was sure it was a good fit, put down a bead of wood glue on the routed edge.
Drill countersink holes for the screw heads then hand screw the panel into place.
I'm using square headed screws for this project. Just started using them. Really like them for two reasons. They resist "cam-out". Cam-out is when the end of the screwdriver slips out of the head of the screw as you turn it. This is both frustrating and can chew up the end of the screw driver and head of the screw. Since there is less cam-out I'm able to reuse the same screws. Since there has been a fair amount of assemble/disassemble on this project the square drive as definitely saved me on screws.
Back Platform done.
The rest of the photos in the posting are in strict chronological order. You'll soon see why I'm mentioning this.
On the Seat Platform the 19/32 panels are going to be hinged so I can access the area under the seat. The hinge works best if it sits flat with both surfaces even.
The edge of the panel does not sit even with the edge of the Seat Platform frame. I could either notch down the panel or raise the edge of the Platform. Notching the panel would leave the wood too thin so I'll raise the edge of the Platform by adding small plywood blocks.
In this picture you can see the three different heights. On the right is the plywood panel that will be the hatch. On the left is the plywood block that will be used to raise up the level of the platform which is in the foreground.
Since the block and the plywood are both 19/32 thick, their difference in elevation corresponds to the depth of the edge I routed out on the Platform.
Set the table saw to the needed width (depth) and run the plywood block through it.
Cut the block into four equal sizes. One for each hinge.
Figure out where to position the blocks.
Can you see what's wrong with this picture??? I didn't catch it.
Glue and clamp the blocks into place. Let it set.
I'm getting ready to start on the the second set of blocks when Quality Control Engineer Bob comes into the garage to make one of her inspection tours.
She takes one look around and then starts raising a fuss.
I don't know what she's complaining about but she keeps at until it suddenly dawns on me what she's saying.
She's saying "Wroooooonnnnggg"
Wrong? What's wrong? Then I take a look at what I was just working on.
D'OH!!! I've glued the blocks to the WRONG side of the Seat Platform!
I quickly unclamp the two blocks then try to pry them off the Seat Platform. I was just able to get them off the Platform. In another minute or two I think the glue would have set and it would have been too late. Needless to say I wasn't taking any pictures of this operation. No time.
Move the blocks to the correct position on the opposite side of the Platform then clamp and glue into place. Here you can see the blocks are on the same side as the hinge marks for where the Seat Platform is joined to the Back Platform. That's what I missed in the previous picture. The main hinge marks.
Glue on the second set of hinge blocks.
Wait till the glue sets up then add the hinges and try it out.
Add a finger hole to be used to hold and raise the hatch.
Watch Bob take a victory lap in the van.