Hey Modutrak guys...

[Sokramiketes]

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These are original 36" radius module frames, but even the 5 foot corners use the same construction with a single center stringer.

[Sokramiketes]

I was just wowing at the 5x5 sheet availability. I'm not completely sold on the need for the top-side plywood, I was thinking foam on frame if the spline is in place. Just sayin'...

There is probably a way to jig up the frame so you don't need the plywood top. But, I am too lazy for jigs...

Starting with a 1/4" plywood top makes for a very positive construction sequence. Everything builds off the top or attaches to the top. It keeps the module square. It takes long screws to anchor the spline while you're gluing it together. It leaves the bottom clean for mounting tortoises and electronics. It stops the legs from piercing the surface.

It also doesn't weigh that much.

If you go the foam route I'll be interested in seeing how it works out. It's doable, but a bit of extra effort.

[Mark W]

Not much extra effort.   Rather than the top layer of ply, I add a 1x2  rail along the sides and endplates.  This acts as a shelf for the foam and makes the 1/4 ply sides very sturdy.  I also notch the cross member so it lines up on the top side, giving extra support for the foam.  The legs attach to the two outer cross members.  The whole things weighs 11 pounds and strong enough to work as a ladder.
If tortoise or accessory mounting is required, I'll add a strip of 1/4 ply between the cross members where necessary. 

[pdx1955]

Having not worked with plywood framing before, do you use a large bed table saw or a circular saw/fine blade combination (or both)? Are the legs individuals or made up leg pair assemblies that just slip in place for quick setup?

[sirenwerks]

The Modutrak legs are a pretty nifty design that is split at the top so one leg bridges two modules. They're also height adjustable to a degree. The design is captured in the club's public forum Build Manual: Modutrak Construction Techniques topic. (http://www.modutrak.com/forums/index.php).

[conrail98]

Having not worked with plywood framing before, do you use a large bed table saw or a circular saw/fine blade combination (or both)? Are the legs individuals or made up leg pair assemblies that just slip in place for quick setup?

I try to get the big box or lumberyard to rip them to the smallest they'll do. I then use the a 100" straight edge I have and a circular saw to rip them even smaller. One hint I found on my woodworking forums is get yourself a 2x8 piece of 2" foam and lay the plywood you're cutting on that. Set the depth of the circular saw blade about 1/8" to 1/4" just below the plywood thickness. Small cuts in the foam isn't a big deal but can reuse the foam over and over and it gives a good, sturdy base to cut on,

Phil

[Sokramiketes]

Not much extra effort.   Rather than the top layer of ply, I add a 1x2  rail along the sides and endplates.  This acts as a shelf for the foam and makes the 1/4 ply sides very sturdy.  I also notch the cross member so it lines up on the top side, giving extra support for the foam.  The legs attach to the two outer cross members.  The whole things weighs 11 pounds and strong enough to work as a ladder.
If tortoise or accessory mounting is required, I'll add a strip of 1/4 ply between the cross members where necessary.

What are the dimensions of that module?

My 18"x60" standard frame is 10 lbs and takes 5 cross cuts to size the ripped material.

With the notching on your cross pieces, are you cutting ~20 times for that frame?  Or are you routing the notches? 

And then you still add pieces of 1/4" for mounting things to the foam?

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[Mark W]

This one is 18x48, with 6" height per Free-moN.

Yeah, it would be about 20 cuts or so, but I jig up stop blocks on the table-saw sled so any repetitive cut is done in seconds.  These last four modules went from ripped stock to assembled frames in about 2 hours total. 

[Sokramiketes]

Well, if you want to use more effort and more time to make heavier modules, then foam all the way!  <grin> 

[Sokramiketes]

Any lumberyard that caters to Cabinetmakers or fine woodworkers should have Baltic birch plywood...

Mike @Sokramiketes  I remember talk of a build manual, was it ever finished? I'm also interested in building some Modutrak based sections...

No, I have a bunch of text but the diagrams were holding me up.  I never found the time to do them right.  The closest thing is the public forum posts at www.modutrak.com