Module Construction 101: Part 2 – Materials & Tools

Part 2 – Materials & Tools
In this session, we'll discuss:

• A note on construction methods.
• Material selection – What’s best in quality and value, and where to buy.
• Tools you’ll need to build the module.

Construction Methods
If you’ve been keeping up to date with Free-mo and peoples construction methods, I’m sure you’ll notice that for every 5-10 people you ask how they built theirs, you’ll get 5-10 different methods. In these articles I will be posting my method which may be one you’ve seen before, or a combination of different ones put together. My goal here is not to tell you my way is the best, but only to show you yet another way to approach module construction.

Some methods may seem like overkill, but you have to remember, these modules are built to be moved around a lot and need to be pretty tough. I have to say though, there are things I wish I had done differently or would have been able to afford. At the time that I built my modules, I was in school full-time and had very little income, so I used lower quality materials and some experimental methods for my legs. My current modules may not have seen many operating sessions, but they have been moved around a lot in the last 4 years.

Where to Buy Materials
It is time to buy your materials for your new Free-mo module project, but you’re not sure where to go for selection and price. First, you can look at your big box stores. They usually have everything you’ll need to build a basic module. Or, if you have a local, independently owned lumber yard, they are a great source for your wood, but not so much for hardware a lot of times. Also, check your neighborhood hardware stores. Now, not a lot of them will carry a large selection of lumber, but they are a great source for your hardware. If you’re a seasoned handyman or DIY’er, you’ll probably already know these things.

What to Buy
The following is a good starting list for your materials. I have tried to include the item, average price, and store where purchased. You may find that prices differ by location, as well as selection, but what’s important are the actual items to buy.

1. 1 - 4’x4’x3/4” Birch plywood panel - No need to get a full 4’x8’ sheet for one module. - $25.00 at Lowe’s or Home Depot. But if a 4'x8' sheet is all you can find, it will run you about $35.00-$40.00.

2. 1 - 4’x8’x2” blue or pink foam insulation board – Sorry, but all I find are full sheets, so if you have some friends building modules too, maybe have them chip in and split the cost. - $25.00 at Home Depot.

3. 2 - 2”x2”x8’ furring strips or 1 - 2”x4”x8 – You’ll need these for the legs of each module you build. I’ll explain more later.- $3.00 at Lowe’s.

4. 2 - ½”x2”x36” Grade Stake or similar material – The only way I have found these are in bundles of 25, but some stores may have them individually. - $10.00 at Lowe’s.

5. 8 - ¼”-20x2.5” Carriage bolts - $0.05 each at Lowe’s. – You can get these individually or in a bulk pack.

6. 4 – ¼”-20 wing nuts - $0.15 each at Lowe’s. – You can get these individually or in a bulk pack.

7. 4 – ¼” flat washers - $0.05 each at Lowe’s. – You can get these individually or in a bulk pack.

8. 4 – ¼”-20 Blind Nut - $0.10 each at Lowe’s. – You will probably only find these in a 2 pack, but a hardware store may have them individually.

9. 1lb. box – 1 ¼” #6 General Purpose Drywall Screws – A 1 pound box is suggested because you may want to use more than I’m recommending. - $6.00 at Lowe’s, Home Depot, or a hardware store.

The Tools You Need
I know that most of you will have just about everything you need to build a module, especially if you’ve built any previous layouts. But, for those of you that are new to the hobby and my not know, or have, the tools needed to build a module, I have created a basic list of tools for you. Use this list to get the tools from the store, your workshop, or borrow from a friend. One thing to remember though, when it comes to tools, you get what you pay for, so try to buy the best quality your budget will allow. This is especially true if you plan on building more than one module, or have other DIY projects to do.

· Measuring Tape – Try to pick up at least a 12’ tape, like one that’s pocket size or even a key chain style. That’s really about all you’ll need, unless you plan on completing other projects that require something more in the 30’ range.

· Pencil – A good pencil will be needed to mark your measurements. You could also use a Sharpie, but you can’t erase a mistake with one of those.

· Speed Square or Framing Square – You’ll need one to make sure your lines and framework are square.

· Straight Edge – Find something at least 4 to 4 ½’ long that is as close to perfectly straight as you can. I use a T square most drywallers use, but you can use a good 2”x4” or maybe a piece of pipe. Just make sure it’s straight. An alternative would be to use a chalk line and snap a line between your marks.

· Circular saw – You will be using this for cutting your frame sections primarily, but it can be used to cut everything else.

· Miter Saw – You will use a miter saw to cut the legs and leg bracing to size. As mentioned, you can use a circular saw to cut these, but a miter saw may make it easier. A small 10” saw will do the job.

· Drill – Electric or cordless, it doesn’t matter, as long as you are able to use various bits in it. For about $50 you can get a Black & Decker combo kit at Wal-Mart and it has an 18 volt drill, flashlight and sometimes a stud finder. Always look for combo kits in any tool you buy. It might be cheaper in the long run for a quality tool with extras.

· Drill Bits and Screwdriver Bits – Primarily in this series you’ll be using a ¼” drill bit and a #2 Phillips screw bit, but you might want to find a decent size set for future projects.

· Table Saw – This isn’t required, but nice to use for ripping panels or sticks of lumber down to size. For some projects, this can be used instead of a circular saw and get the same or better results. They have good quality name brand saws everywhere for around $100 or more. Always look for a sale.

· Saw Horses – This can be as simple as a couple pairs of $5.00 brackets that screw to 2x4’s or as elaborate as some $60 Stanley Fat Max horses. I do a lot of construction work, so I bought the Stanley units. They are very durable with height adjustable legs, storage and places to hold lumber or pipe on the top.

· Extension Cord – They never make the cords on tools long enough, if they aren’t cordless, so pick up about a 10’ cord, or be safe with a 25’ cord.

That should be it for the tools you will need. If I think of anything else I will either update this article or add a note when the time comes.

Next Article
For our next installment, we will talk about preparing our materials. This is going to be the focus of the article and pretty much all it will entail. I might move on to assembly as well, but I don’t want to overwhelm anyone only 3 articles into the series.

Until next time, happy modeling!

John McManaman