I borrowed my friend, Tom's, 1 inch unibit to cut a hole for the grommet in the side skin. My unibit only went to 7/8 inch diameter. Thanks, Tom!

After planing some hardwood down to 3/8 thick, I used the router to route a groove in the edge. The router bit is one of those bearing-guided kind, so the plywood below was what the bearing rode on. It's kind of hard to see, but there actually is a semi-circular groove in the edge.

In the past, when I've used custom bending blocks like this, the tubing tends to flatten out a bit. I believe that's because the sides are not well contained. So this time around I decided to glue on some side guides.