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Good way of attaching side panels without punching holes through them?

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Tahnok:
So my bartop is almost complete and I am considering my next venture (maybe a vertical monitor). One of the little things I hate about both my cabs though is that I had to put numerous holes through the sides for fasteners. I counter-sunk them and filled them with putty, but you can still see them. I am less than a decent woodworker; I don't have experience with common wood joints.

Any ideas/suggestions? I will probably be using 0.5" particle board (or plywood), if that matters.

javeryh:
Use a block on the inside between 2 joints and attach everything from inside the cab.  Imagine putting a block of wood in every corner where two boards meet on the inside and screwing that block to the panels.  I'm probably not explaining it clearly but you shouldn't have to drill through the outside of your cab...

Tahnok:

--- Quote from: javeryh on December 07, 2005, 06:53:32 pm ---Use a block on the inside between 2 joints and attach everything from inside the cab.  Imagine putting a block of wood in every corner where two boards meet on the inside and screwing that block to the panels.  I'm probably not explaining it clearly but you shouldn't have to drill through the outside of your cab...

--- End quote ---
Yeah, that's similar to what I did last time, except I drilled though the outside. It seems like it would be difficult to get it to grab into the side panel from the inside when it is only 0.5" thick. I'm also a bit weary of creating a bulge on the outside where the screw goes in. Is either something I should worry about?

Bones:
Dude,

After experiencing exactly the same problem you described and investing countless hours sanding and painting to conceal the construction evidence, I think next time I will just cover the sides with vinyl or laminate after a rough sand & clean.

You should be able to obtain structural strength and a nice finish without a whole heap of extra work & headaches.

It's just a thought and will definitely be my approach to the problem next time around......

*Edit-Spelling.

Dervacumen:
You can use dowels and gorilla glue.  Even though the dowels will only go in to the sides 1/4" or so, combined with the gorilla glue it will make a joint that you won't be able to get apart.
Lining up the dowels is a bit tricky, but you can get a dowel jig for about $20.  You need to clamp the stuff together pretty tight to get the gorilla glue to really take, so use bar clamps if you have them.

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