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Assembling Monty’s Hugo display cases

Parts:
1 3/4″-thick plywood back 47 1/4″ high, 35 1/4″ wide; 7 holes across bottom, 5 in top edge.
1 3/4″-thick plywood bottom, 35 1/4″ wide, 10 7/8″ deep; 7 holes in front edge, 6 in back edge.
2 3/8″-thick plexiglass sides, 47 1/4″ high, 11 5/8″ deep; 6 holes at front, 7 holes at back. (Note: some of these pieces are countersunk on both sides so they can go on either left or right; others may work on one side only.)
1 3/8″-thick plexiglass top, 36″ wide, 11 5/8″ deep. 5 holes at back, 4 at front.
1 3/8″-thick plexiglass front, 47 5/8″ high, 36″ wide. 5 holes at top, 6 at bottom
2 3/4″-square plexiglass screw bars, 45 3/8″ long, 6 holes + 7 holes, to attach front to sides
2 3/4″-square plexiglass screw bars, 9 7/8″ long, 2 holes + 3 holes, to attach sides to top
1 3/4″-square plexiglass screw bar, 35″ long, 5 holes + 5 holes, to attach front to sides.
49 1″ 10-24 flat-head hex-key bolts
38 2″ #10 wood screws
either
1 3/8″-plexiglass full-width shelf, 35″ wide, 10 3/4″ deep, corners notched at both ends of one long edge
4 3/4″-square plexiglass bars (2 holes) for shelf support
4 1 1/4″ 10-24 flat-head hex-key bolts
or
1 3/8″-plexiglass half-width shelf, 17 1/2″ wide, 10 3/4″ deep, one corner notched
2 3/4″-square plexiglass bars (2 holes) for shelf support
2 1 1/4″ 10-24 flat-head hex-key (“stove”) bolts

CAUTION: to make alignment easier, do not fully tighten any screws until every screw in the case has been started.
WARNING: DO NOT OVERTIGHTEN screws or bolts; threads in both plastic and wood can strip out. Finish tightening screws/bolts by hand.
CAUTION: each screw bar will fit in only one orientation; keep trying different orientations until all the holes line up.

  1. Fasten 2 or 1 shelf supports (depending on whether case will have a full shelf or a half shelf) to back, using 1 1/4″ stove bolts.
  2. Fasten back to bottom with (up to) 7 wood screws.
  3. Fasten one side to back and bottom with wood screws.
  4. Fasten top/side and top/front screw bars to top with 1″ stove bolts.
  5. Fasten top to back with wood screws.
  6. Fasten top to attached side with 1″ stove bolts.
  7. Fasten side/front screw bars to front with 1″ stove bolts.
  8. Fasten 2 or 1 shelf supports to front with 1″ stove bolts.
  9. Fasten front to bottom with wood screws.
  10. Fasten front to top and attached side with 1″ stove bolts.
  11. Insert shelf.
  12. Postion case on table and Hugos in case.
  13. Attach remaining side to case: wood screws back and bottom, 1″ stove bolts top and front.
  14. Finish tightening all screws and bolts.