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Assembling the Module Frame - Part 2: The Front Piece and Back Piece to The End Plate/End Cross Member Assemblies
Our next step is to take these End Plate/ End Cross Member assemblies that we just screwed together and fasten them to the Front Piece and the Back Piece. This is accomplished in two consecutive steps. 
Step 2.1
  • Take three 1½" #6 Robertson screws and screw them into the three vertical holes at one end of the Front Piece so that they just come through the other side of the wood as shown in the photo below. 
  • Take one of the End Plate/End Cross Member assemblies and smear some wood glue on the ends as shown in the photo below.

  • Place the End Plate/End Cross Member assembly  and the Front Piece on edge on your working surface so that you are looking at the "Top" of both pieces. This is very important
  • Move the Front Piece so that the end and the top are exactly flush with the end and top of the End Plate/End Cross Member assembly. This is very important
  • Screw in the top wood screw. 
  • Move the bottom of the End Plate/End Cross Member assembly so that the end is exactly flush  with the bottom of the Front Piece.  Screw in the bottom wood screw, then the middle wood screw. 


Step 2.2
  • Take three 1½" #6 Robertson screws and screw them into the three horizontal holes at the same end of the front piece so that they are not quite through the thickness of the wood. 
  • Place two pieces of scrap wood on the End Cross Member, gently press down so that the scraps of wood are flush with the top of the Front Piece as shown in the photo below.  This will align the End Cross Member so that is exactly 1½" down from the top of the Front Piece (the thickness of our styrofoam)
  • Screw in the wood screws. 
  • With a wet J-cloth, wipe off any excess wood glue.

This is what this corner looks like from the top after we have fastened one end of the End Plate/End Cross Member assemblies to  one end of the Front Piece:

Step 2.3
  • Take the other End Plate/End Cross Member assemblies and, following Steps 2.1 and 2.2  above, fasten this piece to the other end of the Front Piece as shown in the photo below. 

Step 2.4
  • We now have fastened 3 sides of the frame together.  We need to fasten the Back Piece to this frame. 
  • Smear some glue on both ends of the End Plate/End Cross Members as shown in the photo below. 
  • Follow Steps 2.1 and 2.2 above to fasten both ends of the Back Piece to their respective End Plate/End Cross Member assemblies (I've rotated the module frame to make it easier for me to photograph in my "studio".)

We  now have a "square box" that looks like this:
You can check the squareness of our assembly with a T-square.  If we did things right, we should be reasonably square.
All that remaines to be done is to install the Middle Cross Member.