After I felt ok about grain orientaion all gussets were roughed out of the ply sheet (s)
The manual suggests double sided tape to put all 8 pcs of ply together and cut them all at once. I had reservations about this , However , it worked Great ! I ended up buying a roll of carpet tape that was 4" inches wide and 60' long placed three of these on the back of the ply and sandwiched them all nicely.
I should note that while I scaled the gussets to the card board - I rounded up all caliper measurements to the nearest whole number IE - 1. 640 " rounded to 1.7 . I did this becuase inevitably I will try to cut perfectly on the line , its something I do - I dont know why! Anyway all my gussets will be at slightly larger than the required area.
Note : ply was sanded both sides prior to cutting.
