Update 4 - Putting the pieces together
Here it is... the moment of truth... I have assembled the main part of the case/table.
Cut the 80mm and 92mm holes and cut the notches in the bottom piece to allow legs to come up through into the box.
Disk drive tray slot cut out.
It took way too much fidling to get that piece out without destroying it.
There is only about a 1/16" gap around the piece. It'll be practically invisible.
I'm using insert nuts paired with bolts to attach the legs, motherboard tray and HD rack to the computer.
Finished cutting holes in the back panel... it is now about half the weight of the front panel.
The bottom panel sits 1/4" above the bottoms of the side and front/back panels and is notched into the side pieces 3/16".
To hold it all together we need.....
Wood glue... lots and lots of wood glue
It all fits together, glue is now drying, the case is pretty square (actually only about a 1/32" off by way of corner to corner measurement) and it is being held in position by dual straps.
Dual straps... sounds like a bad movie name...