Assembling The Module Frame - Side Pieces - Part 1

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.

We're going to cover the assembly of the side pieces in two blogs, simply because one blog would be quite long to cover, what with the instructions and photos.  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. 

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).

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. 

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 other gusset/end plate assembly. 

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.