Since my last post I have come a long way. I installed all the hinges for both the glass to and the wood lid and the support for the lid. I installed the glass for the shadow box (5mm). built and installed the two drawers with faces and handles. I also installed the plywood base and tray for the shadow box.
First the hardware installation went well, with the exception of the lid support. The lid support was installed on the right side and needed a mortise 3/4” deep, I didn’t think about the two screws that pass though the joint there, nearly ruining a router bit. I had to take a grinder to the underside of the support to allow it to straddle the screws.
Next I installed the plywood bases, this was fairly straight forward and I left a 3/8” gap around the bottom to add a piece later. I did this to save time on the drawer openings, as you can see I was able to cut the drawer openings out on the saw
My next task was installing glass, I used clear sealant and then stapled in supporting strips to secure the glass. Once dried the assembly was stiffened nicely for final installation.
I then took to the task of installing the lower pieces that skirted the plywood and started the drawer build.
The drawer faces were from a book matched piece of elm with figure. I used a biscuit joiner to cut mortises for the handles that I had fashioned from B&WE, then glued them in; the fit was tight but the persuader got them to go in. One bit of advice here, set a stop for the biscuit joiner if you are using it on a face like this; it walked on me and I had to re-sand the drawer faces to remove a gouge.
The drawer body is plywood, and I used centerline wooden runners from Rockler for each.
Finally I installed the top and lid.
I still have a few details but I’m very happy with this build. I can’t wait to see it with the mirror installed, I’m having the mirror engraved with his name, master EOD badge and his highest for medals including a purple heart and bronze star.