Well that's a wrap. The round over with the trim router did almost ruin it with this huge tear out. The transition into the end grain was never going to be great, could have been worse. I had to change the profile to be much more rounded and hand shaped with a sander and manual sanding.

Here's the final product wiped down with some mineral spirits. It's quite sturdy even though it doesn't have a cross brace. I think I could sit on it but not risking it, this isn't meant to be load bearing.

Thanks for following along and the encouragement!

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Oh yeah, the panel glue up turned out nicely. It's a shame that this will get a stain finish ("customer's wishes and he will be committing the heinous act). Its not book matched but I like how the grain flows between the panels (looks better without the blue shop lights as well).

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I think I like woodworking because it's basically just problem solving over and over. In fact there's very little cutting compared to everything else (and also because I'm very slow at it). The alt text describes what's happening in each step (always open to suggestions).
I've pre sanded everything but it'll get a final sand and some roundovers on the top (which is nerve racking as a last point of potential screw up after all this effort).

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So this build (a cover for some equipment for a friend) is coming along. I needed the panel I was gluing up to sit flush with the top of the sides but it needs to be recessed from the front by about 1¾" (4.5 cm). This is an interesting problem to a clean flat cut along the top of the side but a square edge for the panel to sit in. I did the long cut as a stop cut on the table saw and then used the bandsaw to cut it square. The second photo shows how I didn't do a good job, but a lot better than I had originally feared. The test cuts really helped to get close with the approach at least, now if I could only remember to connect the dust collection port to the correct saw while switching back and forth.

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