There is still some way to go before the boards reach the inner race or the axis shaft. This leaves the potential for more material to removed from the miters to sink the boards further. I didn't want to finish the miters to size until I was certain how the outer boards would fit over the inner boards.
An extended line through the miters should pass though the center of the studs.
I am making faster progress on the miters after wasting time trying to plane them from scratch.
An electric jig/stick saw set over to 45° is much quicker despite some difficulty starting each cut. The results are very satisfying provided the saw's sole plate is firmly held down.
Side view of one outer board clamped gently in place between the flange bearings. The sawn miter has been given a couple of strokes of the No4 and No5 bench planes just to tidy things up.
Still too early to worry about a perfect finish and the miters will become glue joints anyway.
I am using a good quality 24" 60cm steel rule/straight edge to check the miters are planed straight and flat. A try square with brass bevel is used to check the 45° angle.
More images tomorrow as I rough out more outer boards.
Getting the miters to a true 45° was difficult with a wood plane. In the end I used the jigsaw to rough out the slope. Then the bandsaw, fitted with a fence, to make the angles more accurate. A gentle skim with a No4 wood plane helped to flatten the cuts along their length.
The image shows the outer boards assembled with the inner boards removed. The kitchen worktop material is not perfectly flat and makes perfect joint closure another problem to be addressed.
I am now considering not using wood glue but adding heavy alloy angle to the outer corners of the housings. Studs with hex socket-head furniture screws would make a neat job of clamping the angles and boards tightly together. I have to be careful to miss the main, longitudinal studs with these cross studs. Not to mention missing the cross studs with each other.
And another image, showing how the inner boards just fit between the studs. These can sink no nearer together because of their miters meeting slightly too early. I re-fitted the fence to the bandsaw and took very thin cuts on the miters. This allowed them to settle slightly deeper together.
Click on any image for an enlargement.