If you look at the model, it has all sorts of craze angles. The walls needed to fit together perfectly around the roof. The model needed to be square.
There are no right angles in this thing. My buddy spent a great deal of time making the walls and was having trouble figuring out how to glue it together. On top of everything else, the wall with the doorway is supposed to slide open after the roof lifts off.
I cam up with the idea of making a jig out of MDF on the shopbot so that you could use it as a form to clamp the sides for support.
This is how it came out...
Step 1: Use VCarve to Drive the ShopBot
This jig was cut from 3/4" MDF on a shopbot alpha. Notice that the slots have dog-bone ends. This allows for the circular bit to provide clearance so that you can put a square right angle slot into what otherwise would be a round hole.
This is how the support is able to be inserted into the base.
The vCarve software allows you to create tabs that hold the whole thing together until you are ready cut the tabs out. Use a jig saw to blow through the tabs like butter.
Step 2: Clamp It to the Form
Once this if done, we tested the roof to make sure that it fit in the model.
Step 3: Use an Air Powered Brad Nailer
We used 5/8" and 1" long brads while the model was still in the Jig
Step 4: Unclamp and Finish
I made the jig at TechShop.