Ok...let's try this again. Pardon th etpying. I had to get 4 stitches in my left index finger today. I didn't cut it on the model. I was opening a baking soda box for our cat's litter box with my pocket knife.
First some metrics.
There are 202 parts. At least they aren't small parts.
Since I don't have a printer that can handle 1/8" corrugated cardboard I printed the Bulkhead parts out on 8.5” x 11” (216 mm x 279 mm), 67 lbs. (147 g/m2) paper, then spray glued the printouts to copier paper boxes. Because of the part size I was only able to get two big parts per box, one on the box bottom and another on the box lid.
There are two variations in Bulkhead.pdf. Part B.4.7-B & V are for the Banana and Veidt variants. B.4.7-A is for the Macintosh. The Mac part had an interruption of the inside of the original Mac 128k. All the people that worked on the project got their signatures engraved on the inside of the case back.
I'm building the Banana PC jr., so B.4.7-B & V will be used.
I found that cutting all the vent slots was tedious so I started laminating parts with slots before cutting the slots (because I have a double wall construction). It worked well. Unfortunately, the top panel is the last part where I can do this. Fortunately, laminating parts will eliminate some interior parts. Unfortunately, that means going back to the Rhino and Pepakura and rearranging stuff. I'll keep pressing on and do that modification for the beta files.
Case Back - Top Panel
Exterior - Apple/Banana/Veidt.pdf
Laminate a piece of cardstock on the back of B.0.2, B.0.3 and B.0.5. Cut out all the vent slots on B.0.3 and B.0.5. There's 44 on each piece and they are 2mm across with 2mm between each slot. After your hand cramps go away cut out B.0.2.
Get more hand cramps by cutting out the slots on B.2.2 I got tired of cutting out vent slots so I removed them from B.3.3.
Laminate B.3.3 to B.4.3 using the back edges for alignment. Laminate B.2.2 on top of B.3.3. Fold the flap on B.2.2 over the edge of B.4.3.
Cut two .25" strips off a sheet of copier paper. Glue them to the back of B.0.2 as shown.
This is where you will glue the handle recess to. After the glue has dried laminate B.0.2 on to B.2.2. The top panel should look like this at this stage.
CAREFULLY attach B.0.3 and B.0.5. You should see a 1mm section of B.2.2 though the slots in B.0.3 and B.0.5. There should be a hairline gap between B.0.3/B.0.5 and B.0.2.
Cut out B.0.4a, B.0.4b and B.0.4c. Score the valley folds on B.0.4b as shown. Use two 0.25" strips of copier paper and attach B.0.4a and B.0.4c to B.0.4b.
Roll B.0.4a and B.0.4c to follow the contours on B.0.4b's middle section. Roll the top of B.0.4a and B.0.4c so that the combined parts look like this.
Slide B.0.4a-c into the top panel recess with the slots on B.0.4a and B.0.4c going over B.4.3/B.3.3/B.2.2. Use strips of copier paper to attach the part.
While I'm looking for something to use as a jig, here's a preview of the case back assembly. The side panels are perpendicular to the bottom and back panels. The top and bottom panels are the same width. Therefore, if you remember your high school geometry, this means that the top panel is perpendicular to the side panels, too.
The back panel's bulkhead (B.4.7 B & V/A) rests on the bottom panel's bulkhead (B.4.6) and is between the side panels' bulkheads (B.4.1, B.4.2, B.4.4 and B.4.5). The back panel's exterior (B.0.1) should be inside of the side panels and the bottom panel's exterior is inside the back panel. This will expose the side panel's edge to the back of the model and the back panel's bottom edge to the bottom. You might have to trim the back panel's exterior to achieve this.
The side panels' bulkheads parts (B.4.1 and B.4.4) rest on top of the bottom panel's bulkhead (B.4.6). The bottom panel's exterior (B.0.8) should be inside of the side panels. This will expose the side panel's edge to the bottom of the model. You might have to trim the bottom panel's exterior to achieve this.
The side panels' bulkhead parts (B.4.1 and B.4.4) fit into the notches in the top panel's bulkhead (B.4.3.). The remainder of B.4.3 rests on B.4.2 and B.4.5. The top panel's exterior (B.0.2) should be inside of the side panel. This will expose the side panel's edge to the top of the model. You might have to trim the top panel's exterior to achieve this.
There is a 0.6" (16mm) lip on the side and top panels. This lip will be inserted into the case front. You may have to trim the lip on some of the panels to have a consistent width.
To summarize: the angles are all 90 degrees, the top and bottom panels fit inside the side panels, and the lip around the side and top panels is 0.6" (16mm) wide.