Hi all,
I bought a Silicon Chip tube amplifier kit from Altronics which doesn't come with an enclosure.

I would like to ask for some help with how to approach making the tube amplifier enclosure in the pdf attached.
tube amp case.pdf
case.jpg

The 2nd page shows the measurements of the case I'm going to attempt to build.

Ideally I'd like to follow these measurements because the kit comes with some machined acrylic parts and a front and back panel designed for this particular enclosure design.

I bought a 150mmx19mmx1.2m piece of DAR Jarrah from Bunnings to use. It should be just enough if I don't make any mistakes.
I'd like to try have the wood grain to flow around the exterior of the case, so I'm going to cut it so it will maintain that flowing grain across the joins.

The main parts that will be a challenge for me are the recessed parts in the front and back and cutting the 45 degrees cuts accurately.

I don't have many power tools, so most of my tools are hand tools. The power tools I have access to are a circular saw, jigsaw and a trimmer router with basic bit set.
I have a 90% finished router table that I've been building for the trimmer router, so if I need a router table, I'll prioritize finishing that.

I have been suggested to cut the 45 degree parts using a table saw rather than hand tools. Another alternative suggested to me is to use a lock miter joint using a lock miter router bit for the 45 degree joint for more strength. I have considered fully blind miter dovetail joints, although I haven't even attempted regular dovetails, so it might be quite a challenge.

The main problem is the front with the back part that the front panel screws into. I'm not quite sure how to do that recess. I'm a bit unsure how easy it is to use a router to do it and how to approach it. I could try chiselling it, but it could be messy although it may not matter if it's covered up but the amp's front panel. If I try to chisel it out, because of the grain direction, I could accidentally split the wood along the grain too, so I'd have to be careful on how I approach it. One alternative mentioned to me is to cut the whole recess out and then later on cut a small same shaped piece of the right thickness from MDF or spare Jarrah and then glue it in as it's going to be covered by the front panel anyway.

The back piece also has a recess, and although I know how to cut the hole in the back piece by drilling and using a coping/fret saw to cut it out, I am not sure about the best approach on creating the recess. I think maybe a router could do it but don't know how to approach that. I could try chiselling it out as it doesn't need to look nice as it's covered up, but it's quite a lot of chiselling.

As for the 2mm wide 9mm deep slot for the PCB, I'm thinking of using a marking gauge to cut 2 lines either side of the 2mm and then follow those lines with a hand saw and then chisel it out with a 2mm wide chisel (I managed to find one!). However, I feel this is going to be quite a challenge to do neatly and at the right depth for the full length of the piece. I think a router bit could do the same job, but there aren’t many 2mm bits around. Maybe I should cut a larger 3mm slot and try find a thin 1mm spacer (some paper?) to fill up the gap.

For the bottom inset part of the box for the MDF base, I have an old record hand plane with adjustable fence and depth that I can use to plane the 9mm deep inset part into the bottom of the front, back and sides. Maybe this can be also used to cut a 3mm slot for the PCB to be filled in with a spacer later.