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Great job! Love everything about this, the repurposed material to the use of a new tool. It had me thinking if making a template might have been easier also would be nice for the repeatable factor. Make one and done cut out the sides put the template on and with a guide bushing on the router run around the inside of the template. You can also step the depths to allow for a small finishing cut to help prevent the burning. Even get the hinges in on that and if you screw up on the template instead of trashing it I've used body filler to put back material from slip ups. Hope this helps. Keep on and thanks.
Great stuff! What CNC did you use? Thanks
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Great job and inventive! I was thinking bandsaw while reading this when trying to figure out how all it was done. Glad to see you didn't cut tiny tiles up then glue them together. Also thickness sander once glued up l know sounds expensive but all kinds of tools worth adding to your shop! Keep it up.
Great post great story and great project! Been wanting to do the same after reading 52 in 52 love the book too. This is pushing me to do one of my own. Thanks