Module frame kit assembly

1. Tools

You will need the following tools:

• a small and a medium size cross head (Pozidrive) screwdriver or an electric screwdriver with corresponding bits.

• tape measure

• wood glue

Not required, but useful:

• steel square

• medium size clamps (2 ea)

Make sure that the surface of the work area is straight and level.

 2. Check the contents

Make sure that all the parts listed in the contents list are in the package. Sort the screws based on their sizes. Note that 3.5x30 and 4x30 screws look very similar. The thinner 3.5 mm screws are intended for the wooden blocks to support the ends of the track base. The thin 2mm screws are for adjusting the elevation of rail ends and will be needed when you install the tracks on the module.

 3. Intermediate supports

Start the assembly by joining the two intermediate supports with a side panel. Note that on the top edge of the supports there are slots reserved for electrical wiring and the two slots should be on the same side of the module. Spread glue evenly on the edge of an intermediate support and secure the support with a side panel using 4 x 30 screws. Use enough force to press the screws to make sure that their heads are at the level of the surrounding surface or a little deeper. Glue the second intermediate support in the same way and finally glue the other side panel to the other end of the two intermediate supports.

4. Wooden dowels

Make sure that there is no saw dust inside the holes reserved for wooden dowels in either the two module ends or in the two side panel ends. Spread the glue evenly in side walls of the dowel holes in the module ends and press the dowels in the holes. If necessary, you can tap a dowel gently with a hammer to force it deep enough in its' hole.

5. Module ends

Spread glue evenly to the ends of side panels and in the dowel hole's sides and press the module end with dowels in place. Note that the alignment holes (brass) of the end must be on the same side with the two slots for wires on intermediate support plates. Secure the end using 4 x 30 screws and use sufficient force to ensure that the screw heads are set to the level of the end plate surface or a little deeper. If the heads are not flush with the end, the two adjacent modules can not be joined without a gap in between. Glue the other module end in the same way. If there is some surplus glue forced out of the joint, wipe the glue off while it is still wet.

6. Elevation of the base board

The elevation of the two supports for the base board defines the vertical position of the track. The module standard assumes that the total height of the track material with the track bed is 6 mm. For commercially available track and track bed materials (e.g. Peco Finescale 55 and Heki 3 mm track bed) the total height is mostly about 6.2 - 6.4 mm. If the combination that you are using falls in the range 6.0 - 6.4 mm, the top of the base board should be aligned with the top edge of the module end plate. This means that the vertical position of top of the base board supports is 9 mm below the top of the module end. Draw a line 9 mm below the top edge of an end plate. If you are using the optional bigger base board covering the whole area of the module instead of narrower strip included in the base kit, draw the line about 35 cm long.

7. Base board supports

Spread glue to the spot where the base board support will be attached on the module end. Make sure that the glue does not penetrate in the holes in brass rings. You can protect the holes with a small piece of adhesive tape (about 5 x 5 mm) from inside the module. Center the support block with the centreline of the two brass rings and align the top of the block with the line. Secure the block with two 3.5 x 30 screws after you have checked that the block is level and properly placed.

8. Frame quality control

Measure the distance between two pairs of the opposite corners. The results should be identical (within 1mm) if the module angles are right. Note that you can correct a small difference and straighten the module when you attack the base plate on the module. It will also improve torsional strength of the module considerably.

9. Base board

Check that the base board fits neatly between the two module ends. The length of the board corresponds very closely the distance between the ends and sometimes it may be necessary to sand the ends of the base board lightly. When the base board is in place, it should not curve the module ends outwards under any circumstances. Spread glue on top of the intermediate supports on spots where the base board will be against them and on top of the support blocks. Place the base board on top of the module centering with the module alignment holes and support blocks. Secure the base board on place with four 3x15 screws after checking that the frame is straight, Place a weight on top of the base board on intermediate supports or use two clamps to force the board together with the supports while the glue dries. If you so wish, you may install additional 3 x 15 screws (not included in the kit) on theses spots.