Thank you all for the compliments!
@bbum and @wesleyjames: I made the design for “medium” (1/8") Proofgrade, and have tested it on the maple plywood and draftboard. Though I didn’t design for a specific tolerance, the pieces aren’t particularly tight with Glowforge’s kerfs, and I bet a little bit of glue would handle a few thousandths of an inch. (The Glowforge kerf was measured to be ~0.01-0.02", so that should far exceed the variability of your material.)
As a side note for everyone, I’ve updated the file to v3.0.1, which fixes some labels and closes up the gaps on the basement door. The old file works perfectly fine, but you might prefer the new one. I’ve also uploaded the AI file for easy editing, and added a changelog to the README and Google Docs instructions.
As with most free files on the internet, QA is participatory: Please post here with what works and what needs tweaking! 