I would suggest buying stock in Gorilla glue, Irwin Quick grips, and a good quality wood filler. This is also a GREAT excuse to buy a good table saw!!
Observations from my project: http://s942.photobucket.com/albums/ad261/33rdsignal/
The original primer colors on the wood are a deep bluish gray, and red oxide. The wood was all primed, assembled and then oversprayed OD(discoved during disassembly)
The metal primer is Red oxide.
Left and Right Sides are 96 inches long by 17.5 inches tall. The thinkness of the wood is 5/8th of an inch.
Forward Panel is 45 1/4 inches long by 17 3/4 inches tall. The thinkness of the wood is 5/8th of an inch.
The panels are tongue and grooved and glued.
Panels are secured using 1/4-20 Step Bolts of various lengths. If the nut will rest on wood they will have a flat washer and a square nut.
If the nut will be against metal, then it is just the nut.
There are no lock washers on any of the hardware securing the wood. The square nuts are staked.
The Tie Downs are secured by Bolts and T-Nuts
Wood is secured by regular 1/4-20 carriage bolts of length. All bolts have flat washers on the nut side. Square nuts are staked.
PRIMER PRIMER PRIMER!! The wood sucks up paint real quick, so prime the wood first, allow to dry, then paint. I have found one coat of dry primer and 2 coates of paint are sufficient.
Broken bolts are your friend, it is easier to replace the bolt then try to salvage it, 9 times out of 10 you will mar up the wood trying to save the bolt.