Back Index Next

1. Drill Pilot Holes for the T-nuts
Select a 1/8" drill bit and drill pilot holes for the T-nuts for the legs in the two End Cross Members, the holes for the Alignment Pins and the holes for the Carrying Plates in the End Plates.  Make sure that you drill the pilot holes vertical to the surface of the wood. If you have access to a drill press, use a drill press. 

2. Recess the Holes for the T-nuts (Optional)
Once you have the pilot holes drilled, you may want to recess the T-nuts below the surface of the wood.  This is optional and is done using a Forstner bit as shown below.  Remember that the holes for the alignment pins are not recessed for one of the Cross Members.

The outside diameter of the barrel of the T-nut is about 3/8". We have to enlarge the pilot holes so that we can insert and tighten down the T-nuts.  Test the size of the drill using a scrap piece of wood.  It's always best to enlarge a hole, rather than try to reduce it, once the hole has been drilled.  Caution - the holes we will drill in one of the End Plates will be less than 3/8" so that the "blunt" end of the alignment pin will fit snugly into the End Plate of the other module

3. Drill Holes for the Leg T-nuts
Select the End Cross Members.  Select a 3/8" drill bit and drill the holes for the leg T-nuts as shown in the photo below.  (Make sure you've tested the drill bit and the T-nut on a scrap piece of wood.
4. Drill Holes for the Carrying Plate T-nuts

Select the End Plates.  Drill 3/8" holes for the Carrying Plate T-nuts as shown in the photo below. 
5. Drill Holes for the Alignment Pins
Select One End Plate.  This End Plate will have T-nuts to screw in the Alignment Pins.  Drill 3/8" holes for the two T-nuts in this End Plate. 
Select the other End Plate.  This  will have a hole to accept the "blunt" end of the alignment pin.  If you use a 5/16" bolt, this hole will be 9/32" to provide a tight fit.  Drill a 9/32" hole to accept the blunt end of the alignment pin.  (Make sure you've tested the drill bit and the T-nut on a scrap piece of wood. 


6. Prepare a T-nut Pull-Down
In order to install the T-nuts, drill a 9/32" hole in a small piece of scrap wood.  We'll call this the T-nut "Pull Down".  We'll show you how it works in a minute.  We'll also need a 5/16" bolt that is 1½" long and a corresponding washer.  Insert the bolt and washer completely into the hole in the Pull-Down.  Now that we have all of the holes for the T-nuts drilled out, we ready to install the T-nuts. 
7. Install the Leg T-nuts

Select one End Cross Member and place the side marked "Top" so that it is facing you.    Mix up a small bit of epoxy glue and spread it around the outside edge of the barrel of the T-nut.


Insert the T-nut into one of the holes in the End-Cross Member.  Insert the bolt into the other end of the hole.  Tighten the bolt until the T-nut is drawn snugly into the hole.  Wipe off any excess epoxy glue.  Repeat the process for the other 3 T-nuts and the other End Cross Member.  The following photos show how to do it. 

8. Install the Carrying Plate T-nuts
Position one End Plate so the the side marked "In" is facing you.  Again, spread some epoxy glue around the outside edge of the barrel of the T-nut, insert the T-nut into one of the holes for the Carrying Plate, insert the bolt into the other end of the hole.  Tighten the bolt until the T-nut is drawn snugly into the hole.  Wip off any excess epoxy glue.  Repeat the process for the other 3 T-nuts and the other End Plate. 

9. Install the Alignment Pin T-nuts
Select the End Plate that has the 3/8" holes for the Alignment Pin T-nuts.  Again, spread some epoxy glue around the outside edge of the barrel of the T-nut, insert the T-nut into one of the holes for the Alignment Pin, insert the bolt into the other end of the hole.  Tighten the bolt until the T-nut is drawn snugly into the hole.  Wipe off any excess epoxy glue.  Repeat the process for the other T-nut. 

Now that we have all of the T-nuts installed, you are 2/3 of the way through the most difficult part of our module construction.  The next step will be to locate and cut out two holes for our RJ12 telco jacks and to recess these holes so that the face plate of the jacks will be flush with the surface of the wood.