Team Gas Diary's

[Gaseraki]

Howdy PJ
The bulkheads are Nylon and I cut them with a router and a large spirit level ruler (picture related)
Professional-Spirit-Level_large.jpg
Placed the ruler about 5cm away from the cut (way my router is setup)
Secured very tightly with heavy duty G clamps (bit of scrap wood to not damage the ruler and the bench)
Push firm and cut with the router.

Happy with the results but as expect few MM off here and there without CNC cutting. So I bolted the bulkheads together and filed them down till they were all quite identicle
Hope that helps

#edit
Sorry you quite clearly said everything rather then just the bulkheads
Big thanks to loads of the straight cuts to my sliding mitre saw. Made life a lot easier and it has a large slide function. But as I said nylon is very scary to cut on it. Have to cut very slowly or it catches rather then cuts.