Yesterday, before getting the axle moved back closer to the center, I used the wall I cut with the router compass (made last week) as a template to cut 2 more walls. The first one will always be my template. It literally takes about 20 minutes to lay down the template, trace the outer shape, cut with a jigsaw, and then move the template to the bottom, clamp and do a finish pass with the router and a flush trim bit. Now my sides are identical. Still holding off on cutting the doors because I need to know for sure where the wheels and fenders are going to land. I want the doors as far back as possible.
Duplicating walls starts with tracing the shape of the template onto a new sheet of plywood.
Then just quickly cut off the waste with a jigsaw. Accuracy doesn’t matter so no need to go really slow and get it perfect. Just stay on the outside of the drawn line.
Stack the new wall on top of the template and align the bottom edge and corners to get the new wall in place.
Do a final router pass to remove the ragged cut made with the jigsaw. Here is an example where I stopped in the middle to show how exact the duplicate will be.
Now I need to do the same with the interior 3/4″ frame sheet. …but that is on hold until I get the new axle and mount the wheels and fenders. Only then will I be able to really see if my new door design is going to work. Also, need to create hardpoints with solid oak plugs where the fender mount points go. All hardware (i.e. door latches, hinges, fenders, lights) will be supported by solid oak hard points rather than plywood, which can be unpredictable in strength.