I did not try to sand or otherwise "fix" the edges of my panels. I left them as is, and have been concentrating on trying to get the panels to stand aboslutely streight.
I think I have pretty much good news to report. I was really careful putting in panel 2. That streightened out the top, so it's now at 90 degrees to the side. I also got panel 2 in, and it is standing at 90 degrees as well. Just put in panel 3 this morning. It too is standing at 90 degrees.
Good news all around... The thing that bothers me is that I am NOT a very good carpinter/craftsman...and I have made a bit of a departure from the plans. Always cause for worry in my case.
The departure is that I did not screw panel 2 or 3 to the side or top of the cab. I used clamps only. Here are a couple of pics of how I put panel 3 in place:
http://www.frappr.com/?a=viewphoto&id=1 ... id=3541324
http://www.frappr.com/?a=viewphoto&id=1 ... id=3541333
Since P2 is closer to the edge, I used more long clamps with it, including one to hold it in place against the top and helped to square it.
In both cases I used the big yellow rafter square clamped to the panel to make sure it sets at 90 degrees.
To hold the panel in position against the top, this little adjustable angle clamp has been a huge help:
http://www.frappr.com/?a=viewphoto&id=1 ... id=3541334
So far, speed seems to be the only obvious downside to this approach. I can only do one panel at a time. Once I have a panel glued-up, I need to leave it overnight, until the PL has completely set before going to the next one. That contributes a bit to my "worlds slowest builder" nomination, but it's about as fast I as should be going anyway.
I also could not use the quick setting PL, since in the case of both panels, it has taken me about 10-15 min to get everything exactly in place and clamped down so that I can leave it for the night.
This seems to be working well...but being a noob, I am very nervious about not using fasteners to hold the panel to the side. The reason I left them out is twofold. First, the panel seems to be solidly in place without them. 2nd, and more importantly, I am afraid that if I use the screws, it will pull the panel down so solidly against the side, that it could pull it out of 90 degrees, since the edge of the panels is about 88 degrees.
So...this seems to be working, but, in the spirit of full disclosure, I wanted to run it by the better woodworkers just to see if you guys see some terrible mistake being made that I have not noticed.
So...hoping this is a "tip," and not merely a warning to others...but you'll tell me
