The next thing to tackle is the front and top of the box. Ideally this needed to be hinged in two places, but also lightweight enough to open easily and not add too much weight.
With that in mind, using 1/8" plywood keeps the weight down, but it has a reasonable amount of flex. Fixing piano hinge to the back keeps the whole length of the top piece supported, but fixing it isn't that simple as it's not got enough depth to screw into.
To get around it, pop rivets with washers at every hole hold it in place securely and stiffen the top of the back panel.
The front and top are hinged the same way before they're attached to the box itself. The downside of this method is that removing the 'door' is extremely difficult, but it shouldn't be necessary.
When the Box is in use the door needs to stay up, propped on the top edges as the cables will come through the front as the server and switch will need airflow.
The door also has a hole in the front to make opening it easier, Another 1" forstner hole is enough for the weight of the door.
And a couple of notches in the top stop the door sliding down onto the cables.
With airflow in mind, the back also needs to be cut for exhaust to allow air from the switch out and power and uplink cable ingress.
Once again, the router makes short work
Not much more to do now (at least not on the list anyway, many hours) and it'll be finished*
(* Finishing is neither guaranteed nor 100% likely to avoid a v2 being made)
Last job for this visit to the workshop is some wheels, this'll make it far easier to load into the car, as well as the cupboard.
Finally, fully loaded ready to be packed in the car and brought home.
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