Railway Bob's Module Building Tips: Assembling The Module Frame

Not to beat the subject to death, but the edges of the gussets and the end plates must be flush with each other as shown in the photo below. If they aren't flush, we will have problems assembling the side pieces. This is where a little bit of time, patience, and sanding pays off.

This is where a second pair of hands would be very helpful. So, don't hesitate to call in your "significant other" or a buddy to lend a hand.

Before we get started, make sure we have all of the tools, supplies, bits and pieces all together - screws, screwdriver, wood glue, shop rag, bowl of water, measuring blocks.

Loading The Screws & Applying The Glue
1) Screw in the 12 screws into the holes of one side piece as shown below - 6 screws on each end. The screw tips should be flush with the "In" side of the end plate but you should not be able to feel them with the tips of your fingers.

2) Repeat Step 1) for the second side piece. Your two side pieces should now look like this.

3) Liberally apply glue to one edge of the gusset/end plate assembly (the pieces we glued together in our last blog).

Lining The Pieces Up & The Vertical Set of Screws
4) Place the gusset/end plate assembly "Top" down (ie "Bottom" up) on your work surface.
5) Place the measuring blocks on the "In" side of the assembly as shown below.
6) Place the side piece alongside the assembly.

7) Place the side piece alongside the gusset/end plate assembly so that the edges are flush with each other. Make sure that the "`Bottom" is facing you (ie "Top" is down). Hold the side piece and assembly tightly together so that the edges are flush with each other. Screw in the vertical line of screws starting with top screw - all the way in. Next, the bottom screw. Lastly the middle screw. You may have to fine-tune the edges as you go from the top screw to the bottom screw.

The Horizontal Set Of Screws
8) The corner edge of the gusset may lift off of the measuring blocks. Push down on the corner of the gusset and turn the screw all the way in. Next the middle screw. Lastly the 3rd screw.

9) Make sure all of the screws are tight so that there are no gaps between the side piece, the gusset and the end plate.

10) Wash off excess glue.

11) Repeat steps 3) to 10) for the other end of the side piece and the corresponding gusset/end plate assembly.

Installing The Second Side Piece
We now have the two gusset/end plate assemblies screwed and glued to one of the side pieces. Next, we install the second side piece.

Now that you have the technique of assembling the two gusset/end plate assemblies to one of the side pieces, we'll now attach the second side piece to complete our module frame. Here's where "time is of the essence" as we will concurrently have two assemblies loaded with runny glue, two ends to get aligned almost all at once, and 12 screws to drive home, and, all the while, trying to keep everything square and flush. It can get a bit tricky but, now that we've mastered the technique of assembling the two gusset/end plate assemblies to one of the side pieces, we should be able to complete the task relatively easy.

1) Liberally apply wood glue to the gussets at both ends. It will take a bit of time to complete the fastening of one end and we don't want the glue on the other end to dry out in the meantime. So, liberally apply wood glue to BOTH ends.

2) Place the 3-sided assembly (two gusset/end plates and one side piece) on your work space with the "Top" down (ie "Bottom" up).

3) Place the side piece alongside this assembly and make sure that one end of the side piece is flush with its matching gusset/end plate assembly. Make sure that the side piece is "Top" down and "Bottom" up.

4) We first tighten the vertical set of screws. Tighten the top screw, next the bottom screw. The assembly may require some adjustment to ensure that the edges are flush with each other. Lastly, tighten the middle screw.

5) The corner edge of the gusset may lift off of the measuring blocks. Push down on the corner of the gusset so that it rests flat on the measuring blocks. This may require some force. Turn the screw all the way in. Next the middle screw. Lastly the 3rd screw.

6) We now move to the opposite end of the last side piece and tighten the wood screws. First the vertical line of screws. Make sure the edges are flush with each other. The process is the same as at the other end.

7) Next, the horizontal line of screws. Press down on the end of the gusset to make sure it sits flat on the measuring blocks.