How to ensure you mark the same point on each side panel?

[ugleymatt]

I'm making a bartop and have my side panels cut out using a combination of jigsaw and circular saw. However i don't think they are identical. I've recently got a router and template cutter so my plan is to go around each one to ensure they are a 1-1 match.

I then had a thought, how do you ensure that the placement of batons, internal bits and pieces etc are in the same place on each side?

Do you just measure from the same point, this would be hard though as you have rounded corners so it would be possible to not get the same spot for measurements.

I did think one way would be, after the sides have been clamped and routed to then drill very small holes in a few places so that they would become reference points for all internal measurements. Then they would just be filled prior to artwork going on.

I suspect i might be over thinking it, so looking for suggestions.

[lilshawn]

mark a centerline in both directions (+) and make your measurements from there. it's easier to measure and get the same point from a line than it is on a radius.

alternatively, print your entire layout on paper and apply it you your workpiece.

alternatively again, make one good piece ( with screw holes and everything) and use it as a template to create 2 identical parts from it.. if you use a piece of MDF or plyboard, you can easily mirror the parts (left and right sides) by simply flipping the board.

Ideally you want to design your things so that you really don't need to fuss and measure out exact positioning of battens and holes and whatnot. I made my cabinets so I can just simply align the batten on the edge of the piece and staple it on... subsequent parts self align to the edge and can be simply attached.

If I drill a hole, I have a jig. It is designed to self align to an edge and positions my bit where it needs to go. This one shown is also designed to do 2 sides so to do the other side, just flip it around and use the other hole. Mind you, I'm doing more than one cabinet, but in the interest of speed and consistency, I have jigs, templates made up for everything...control pieces I use to align parts so they are centered. All the cabinets come out identical.

[UEDan]

My baton were mostly 3/4" from the edge. Used scrap MDF as a guide. Stuff perpendicular to the edge was just marked

[mahuti]

I did think one way would be, after the sides have been clamped and routed to then drill very small holes in a few places so that they would become reference points for all internal measurements. Then they would just be filled prior to artwork going on.

I've drilled through items before to make them match exactly. I figure if I'm going to be using bondo & painting black anyway, what's the difference? Jigs are great though if you plan on doing this again. I've never regretted making a jig, but I have regretted putting extra holes in stuff 

[ugleymatt]

Thanks guys, seeing as i am going to be filling, painting and covering in viynl, making holes/templates makes sense in order to get the cabinet just right.

Least i know i am not crazy...well

[Slippyblade]

Least i know i am not crazy...well

Nope!  Most of us have asked that same question at some point.

[mahuti]

Just FYI. You are in this hobby so... crazy. Sorry man. We all suffer.