Heh, there's enough of us that brew, that we could make a very nice 10 gal automated system out of the spare stainless kegs that I have stashed in my basement.

But yeah, I'd be game at doing a bunch of these at once.

mmm big brew sculpture......

Just some thoughts.

The box joint should be plenty strong enough with Ply.
3/16" masonite should also be strong enough as long as you don't stack too high.
You could do all of it with a circular saw. But I'd get a dado blade.

Now I'd use 1x6 (yes you lose 1/2" in height) with dovetail joints. I'd take Mark up on his offer with the router table and the dovetail template and Theo's table saw.

I'd love to be able to take Mark up on his offer, but we need a place to put it first!

Love the table saw. LOVE IT. Also, I think I already have a dado blade; if I'm right, it'd just need to be swapped in. (haven't used it yet)

jude, my concern with the masonite was wet durability, not strength. i wasn't too clear on that, but i think that 1x6 will be prettier. i just prefer solid wood over ply for looks where it's not a performance/structure issue.

totally not needed, but you could always just put 2x2 frame and make them last awhile; and you also get extra space to add some padding. but it would not look as fancy o.o