A long session of scroll saw use left my hand bruised and sore as the 4 sheets of MDF flooring were cut using a printed template on one pair and transferring the cut parts to the other. Two registration holes were drilled all the way through for long M4 screws. Preliminary sanding of the top and handle area followed and we are left with a frame that can be clamped together and sanded to final dimensions.

First the elastic bands were fitted to their slot, with some more room made at the anchoring point.

Then the slot for the main motor was sanded to a tight fit.

The slot for the rechargeable battery followed, with provisions for locking into place and a tensioning rubber slug.

Finally a cylindrical slot was cut for the keyed main power switch.

The large space for the magazine proved much harder to finalize, with an entire day dedicated to it and a custom sanding drum constructed, to mediocre results. The technique of using a hacksaw blade in a rasping motion was more effective, but it still involved much back-and-forth between registration, clamping, checking, de-clamping and actual work.