A recent discussion on the S&SSofNC group prompted me to develop a BOM for a 30" x 96" straight module
2 sheets 48" x 96" 5.2mm lauan underlayment plywood required - nominally $10.00 each at the big box stores.
May substitute higher grade 1/4" plywood if desired
Cutting list: cut two 30" x 96" pieces... one from each 4'x8' sheet
Cut 3-1/2" x 96" ribs/rails material out of the remaining 18 x 96 pieces - yields ten pieces
four pieces are needs for the rails - 2 outside and 2 inside rails
remaining pieces may be cut to length (nominally 9" and 12") to provide materials for the ribs
2 - 3.5" x 30" good grade (marine) void free 3/4 plywood - a 2' x 4' Handi panel yields 6 pieces
4 - 1" OD x 1-3/4" steel or aluminum tube - note that banquet table legs are constructed on 1" tube. I routinely cut a 1-3/4" piece off of each leg and extend the banquet table legs with tubing that either slides inside or outside the 1" tubing. An appropriate size dowel or broom handle may also be used.
If you have sufficient woodworking/cabinet making skills it is possible to build an acceptable module right out of the gate that you won't have to trash. A number of S&SSofNC people have done it. One must be meticulous with regard to dimensions, squareness, flatness. A good saw and accurate, disciplined setup procedures go a long way towards success.
