Ok well the sheets got cut today; I had to clean the porch to work to mess it up again.
However with a skill saw I still manage to get cuts within 1/8th of an inch;
My method of measuring is meticulous I use the factory cut edges of the boards in order to setup a guide. I lined the corners up flush to the guide; the cut board; and the support directly on the chairs I used as saw horses.
From there I do the following:
Measure the saw blade to the rim of the saw to determine the distance of the blade to the guide depending on which side of the board I'm on (I account of the thickness of the blade)
Basically if I'm cutting from the 4x8 sheet and the guide is on the outside the cut. I need to factor in the thickness of the blade plus the distance to the guide from the rim of the saw. If the guide is sitting on the board and I'm trimming it to size; I factor out the blade and just use the distance of the blade to rim.
I make two markings on the cut sheet the guide arrows and cut arrows using a tape measure.
I place the guide down and line the board on the center of the arrows and clamp down.
Here is the tedious part:
I use a block to nudge the board into alignment before while and after clamping it in place; Then I cut a test notch; measure my board; adjust if necessary; then rip it in a few seconds maintaining and even level pressure perpendicular to the cut.
Spend 10-20 minutes measuring; and a few seconds cutting.
I speed things up as I get going I will assembly with minimal screws tomorrow.
I've already figured how the box is going in; I will have to take off my passenger door to do it; along with the seats out. I will have some more interesting pics tomorrow.
The guide is on the outside of the cut here. To keep the saw from binding, the support is at the guide; this will pull the board away from my blade to keep it from pinching; another chair that is slightly smaller is there to keep it from bending too far and from falling.
Here is a picture of the test cut and measurement; This one was spot on at 34"
Note the guide was on the inside of the cut here; the blade is on the outside; distance of the blade to the rim was 1 1/8th inch plus 32 and 7/8" (the guide position)
Thanks for looking