The top box needs a lot of work. There's some .060 aluminum sheet involved, and I happened to have the side panels of an aluminum tower PC I had saved for just such an occasion.
Bandsaw loves aluminum.
These panels of aluminum get a 90' bend 0.69" long to match the thickness of the plywood minus the thickness of the aluminum...
And then the plywood panels get a .060" thick relief cut milled out of them. Pardon the fuzz.
One pass of a knife cleans the fuzzy edges up nicely.
The resulting shape of the marquee wings is... well, just bear with me and it'll make sense in a bit.
Here's the payoff. The 0.69" deep pocket I've just made allows the 0.060" thick end caps sandwiching the top monitor to look like they are a full 0.75" thick, and thus that the top monitor is almost 1.5" narrower than it really is. The T-molding will get heavily modified and wrap around the outside edge, and laminate will cover the outside flats, collectively hiding the aluminum.
There are some pucker-inducing critical dimensions being set here.
I've lashed the cabinet together with clamps again, in part to check for dimensional problems, but in part because not assembling it
has been driving me crazy. Here is how the top box winds up - the pocketed side panels line up with the knife-edged speaker shelf and the VESA mounts for the
upper monitor. (The transverse 2x4 isn't screwed into the brackets yet, so it's hanging low, just sitting on top of the verticals.)
The satellite speakers fit behind the grills on the speaker shelf, in front of the TV, behind the top monitor, with *this* much clearance. (grin)
Here's the complete cabinet mockup, as clamped up. Getting there.
On the right side, we can also see the power entry box in the lower right corner. This is a pretty good view overall to get the proportions and scale of the thing,
now that it is starting to block out volumes and sillouettes like it will in the end. To further visualize this, permit me a tiny bit of photoshop...
Here are three flat polygons to block out the top screen, main screen, and control panel front wall. This gives a much better sense of how the proportions should look.
Due to the top box trickery, though the top monitor by itself is 30.125" wide, the entire cabinet at it's widest point is 30.250" wide.
Continue...