Reduce the backyard monsters hack tool direct thickness of some off cuts until they perfectly fit in the groove and hold the steel rod captive.
I followed that up with two chess sets.
I didn't risk drilling all the way through from the inside and then using that hole as a reference for the 1/4" bit because I know my luck.
Before I added any glue, I made sure my sides were in the right order for my continuous grain fetish.With enough space between them and the center strip so that they are able to rotate open.I found the easiest order of assembly to be starting with the center divider and side connection points.Adjust your fence and re-cut as necessary until you have a groove wide enough to accept the 1/8" steel rod.Spread some glue on the filler strips and push them in until they rest against the steel rod.My immediate idea was to make a two player configuration for simultaneous play, which it turns out isn't an original idea at all.
I just broke all the sharp edges by hand with 150 grit paper.
Make the second cut.Whenever I use mitered corners, I add miter splines.The last step is to cut the bottom panels to size.I lined the box with felt from Michael's.I started with the miter cuts since I knew the end grain would suck in some of the glue.Bolt cutters made quick work of the cut, but an angle grinder with a cut off wheel or hack saw would work just as well.Lastly, I just moved this forward and back within my layout lines until I had what I liked.Once the glue dried, I sanded the plugs flush with the side of the box.Lastly, I run each corner through the saw.I make my first cut on the left side of the miter sled and then my final length cut on the right.