Thanks crazyD... must admit that the laser makes the repeatable cuts easier, however, the way I do it it's worse on the laser as the layers need to be assembled. 
I made a video of the trials and tribulations of assembling this box.... it craps on a bit but nowhere as long as it took me to glue/assemble the box.  Many mistakes made, however, ironed out to come up with a more viable design.

If your first cut is too short... Take the second cut from the longer end... LBD