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Spent 11 hours fixing a hinge gap my cardboard mockup never showed
Built a quick mockup for a storage cabinet lid using leftover shipping box material last Tuesday. The cardboard sat perfectly flush so I went straight to plywood, but the real lid warped about 3 degrees at the hinge line and now the door rubs against the frame. Took me 11 hours of sanding and shimming in Austin before I realized I should have taped a second layer to the mockup to mimic the thicker wood. Anyone else had a prototype that hid a flex or weight issue until you used the real material?
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