Speaking of digging myself a hole, that's exactly what I've done here. As you remember from the last picture, that piece was for the top or bottom. Well, after looking at it for a minute it hit me....the edge of the material is right near the edge of the door frame. Why is that a problem? Because the lock bolts need some kind of clearance in that same area. So now what?

What I came up with isn't the best fix in the world but it will work. I'm going to make some clearance for the lock bolts by making a cut-out in the top and bottom interior pieces. I placed this piece on my milling machine, clamped it down and then cut the two slots that you see below. After sanding away all the rough edges and foam, I'm ready for round two with my material.

I cut the material around the slots very carefully, sprayed some more glue, and then stuck it all back down one more time. I got into high gear again and didn't take a picture of what it looked like but I can give you a visual. Picture if you will the two cut-outs, they are about one inch wide by one inch deep. And the lock bolts work great now that we have plenty of clearance for them. So far so good. But.....now you can see the metal of the safe box under the interior pieces because of the open slots. Well that's not good but I can fix that too.

Is it just me or do I seem to be "Mr. Fixit" lately?
 

For this fix I'm using more wood, two pieces each to be exact. I glued two pieces together (you can see the line between them if you look close) machined all four edges on my milling machine, sanded them both, and now I'm ready to cover them with material.
 

I mixed some epoxy, smeared it on the back of the wood, cleaned the area with lacquer thinner and then stuck it on the box. This epoxy sets up quick, about five minutes working time, which was perfect. Once I had one in place, I waited about 10 minutes, turned the box over and repeated the process.
 

For the sides I used Velcro in two spots each to keep them in place. As for the other pieces, they will stay in place because the others are trapping them so they can't move. At this point, the interior is finished but I'm not happy with it because of the lock bolt problem. Plus it's getting very close to Christmas (December 21) so I had to work quickly. With that being said along with all the problems I'd been having, I'm starting to "get over this project", which doesn't happen to me very often.
 

It's Finished

One of the last pieces to go on was this piece of plexiglass. I had it in a safe place (no pun intended) so it didn't get scratched. You see that blue tape with the info on it? The 'number one' goes upward and the 'out' faces outward. The reason for the 'out' is because the threaded holes are not in the center of the plastic. The flathead screw heads are right at the edge of the box once I was done chamfering for them. That made the centerline of the screws off-center in the plastic by a small amount. I took all this in consideration when I was working on it awhile ago.