Keep after it Brent. I have really enjoyed following ur project.....
I'm glad someone is enjoying my misery
The water jet CNC did the trick. All the boards are cut out.
However, the CNC could not make the ~9 degree angle cuts I needed along the bottom of the "side wall" pieces, to match match the angle of the existing fiberglass roof. So, now have to call around to find a shop that can cut a 4.5" thick board and make these angle cuts.
I haven't tried the fit yet, but they were able to make the curve cuts on the bottom of the front and back pieces to match the existing fiberglass roof. However, I haven't actually tried to see if my measurements were accurate enough for a good fit or not.
Assuming I can get the angle cuts made at some shop, and that the curve cuts are already close enough, the next step will be to use aluminum tape to hold everything together and fiberglass the exterior of the insulation "assembly". I'm also thinking of adding a couple of layers of fiberglass to in interior as well, for extra support. TBD, as the interior is already going to have a plastic sheeting applied as the finish layer either way.