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Thank you for choosing our plywood stacks. These are not hard to build, but
do take a little time, so a bit of patience helps. We recommend building one
or two to see how the process goes, then set up an assembly line to make the
process a little faster and more enjoyable.
After we wrote the instructions for the early kits we discovered a simpler
way to build these stacks. Follow along as we build a single plywood stack.
Wrapping the Stacks
Each stack of plywood is wrapped with a metal band that is usually black.
These bands prevent the boards from slipping and falling off during transit. We've
provided thin black thread to represent these bands, and the steps below show
how to apply the thread.
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Figure 1: You'll want the bands to be spaced the same
distance from each end for each plywood stack. We've provide a simple
template in the instructions for the kit. Use the lines on the template to draw marks on the
bottom of the plywood stack, as shown here. |
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Figure 2: Extend these two marks to lines across the bottom
of each load. This is where you'll glue the thread used to represent
banding. |
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Figure 3: Insert one end of the thread into the tip of ACC
glue to get a drop of glue on the edge of the thread. This will allow
you to glue the end to the plywood without a puddle of glue. |
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Figure 4: Place the end of the thread along the line you drew
on the bottom of the stack and press it into place with a toothpick,
rolling the toothpick a little to keep it from sticking. Let the glue
harden for about 10 or 20 seconds before you do anything else. |
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Figure 5: Pull gently on the thread as you wrap it around the
load, keeping it taught. |
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Figure 6: Apply a small amount of glue on one side of the
thread. It's best to put this on the "outside" edge so the glue won't
interfere with the dunnage you'll be installing next. |
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Figure 7: Once the glue has hardened for 20 seconds, gently
pull the thread to the side and use a sharp hobby knife to cut it flush,
as shown here. |
Adding the Dunnage
The boards placed under stacks of plywood are called dunnage. Their purpose
is both the keep the plywood dry and to allow room for the forklift under the
load.
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Figure 6: Cutting the dunnage into short strips is much
easier if you have a tool like NorthWest Shortline's Chopper, shown
here. You can easily set the correct width by placing the cutting blade
in the down position and placing one of the stacks next to the blade.
Snug the stop against the other side of the load and tighten down the
stop. |
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Figure 7: Now simply chop the supplied strips of wood into
these short lengths. |
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Figure 8: Apply a bead of glue, such as carpenter's glue or
white glue, along the inside of the banding, as shown here. |
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Figure 9: Place one strip on the inside edge of each thread,
as shown here. |
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