- 1). Cut the edges of each plywood sheet and foam pads at a 45-degree angle. Angle the blade at a 45-degree angle toward the fence. Position the fence on the table saw 25 inches away from the blade for the plywood and 23 inches away from the blade for the foam pads. The original dimensions of the plywood and foam will not be altered and all of the angles are cut on the same side.
- 2). Set four plywood sheets on edge and form a square with them so their angled edges are against each other. Position a corner bracket over each corner so they are centered on the corners, 1-inch away from the edges. Screw eight screws through each bracket so eight screws enter each sheet of plywood.
- 3). Lay one more sheet of plywood on the square frame that you made in the last step so the corners are flush. Position your last four brackets over the corners following the same process you did in the last step to screw this last sheet of plywood to frame. This is the bottom of your protective wood case.
- 4). Turn the case over and lay your last sheet of plywood over the opening so the edges are flush. This is the lid to your case. Position the hinge over any corner and screw it to the case and the lid using the screws provided.
- 5). Spray the inside of the case with your foam and glue a foam sheet to every surface inside. The corners of the foam inside the case should meet at an even, right angle. Let the glue dry according to the instructions listed on the spray can. Spray the inside of the lid with your spray adhesive and position your last sheet of foam on the lid so it is centered, 1/2 inch away from the edges of the lid.
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