Thanks Shackman.
Progress has been slow lately because of work and my dremel died on me also. I'm borrowing one tonight to cut the hole for the face, though.
I'm going to pick up some epoxy resin this weekend and fill the exposed lip you can see around the top bin after I thread and seal some bolts through it at the corners and sides. These will thread through the bottom bin lip and then nut together. I like the idea of having him still able to come apart if I need him to.