My first module is a simple straight module, quite naturally, as these are rather easy to build. The construction itself is straightforward, and the important thing is to ensure that all angles are spot on and that the module is not lopsided or twists during construction.

The end caps must follow the modular standard, and you have a choice between several different profiles. I chose the B96-profile, which is a little hilly and fits well with the terrain here in Norway. There are finished end caps to buy, but it is much cheaper to make your own. The various profiles are available on the Internet as downloadable PDF files for print full size, but I bought a pair of finished end caps to use as templates.

The end caps should be solid, as they will bolt together with the next module, so they are made of 12 mm plywood. A full sheet of plywood measures 122 x 244 cm and is quite unwieldy, so I decided to cut up the whole sheet into smaller pieces (fitting two end caps on each piece) while I was at it:

Cutting the plywood

Then it was just a matter of cutting the end caps and trimming the profile to match the template:

Trimming the profile

The rest of the module is made of 9 mm plywood, except the subroadbed, which is 12 mm for stability. The modular standard dictate longer modules have evenly spaced supports for the subroadbed, and the pictures show the supports fitted with triangular brackets for extra security. The corners have wood blocks for support, and all screw holes are predrilled to prevent cracking:

Supporting the subroadbed

Almost finished module frame

As wood is a living material, it should be sealed against moisture, so I painted the frame before going any further with the construction. In the picture, the terrain profile is finished and cork roadbed is glued in place, and on the underside of the subroadbed I have glued a couple of extra blocks in addition to the support block at each end. These additional blocks create a protective space for the electrical wiring at each end, and there will be a small plate for fixing the 4mm male/female connectors towards the next module:

Module painted and roadbed glued in place

Part 2 will be about electrical wiring of the module.

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