Load Frame Fabrication

12" x 24" x 1/4" Lexan Sheets (Quantity = 2)
2" x 2" x 24" long wood (any species); cut into four 1" long pieces (exact), and two 8" long pieces (approximate)
#8 - 32 x 2.5" Wood Screws (Quantity = 4)
#6 - 32 x 2" Machine Screws and Nuts (Quantity = 4)
Drill (drill press and hand drill)
3/16", 5/32", 1/8" Drill Bits
Screwdriver

Cut the wood into four 1" long (exact) and two 8" long pieces if this needs to be done.

EQUIPMENT

INSTRUCTIONS

Drill two 3/16" holes through each 8" piece (see diagram). Use the drill press.
Using the 3/16" holes of the 8" piece as a rough guide, drill two 1/8" holes 1" deep into the underside of only two of the 1" long pieces (see diagram). Use the drill press.
Screw in a #8-32 x 2.5" wood screw through the 8" long piece and into the 1" long piece for each hole as shown in the diagram. Assembly of the two bottom wooden supports should now be finished.

Align the two wooden supports on one lexan sheet so that there is an 18" span measured along the inside of each support: approximate symmetry (see diagram). Mark where the holes on the wood are on the lexan sheets for drill guides. Do this for both sheets.
Drill the two lower holes on the lexan sheets using the 5/32" drill bit and the hand drill. Drill slowly and in short bursts so that the lexan will not melt. These holes are for attaching the bottom Supports.
Place the other two 1" wood pieces on the top corner of the lexan sheets and mark the holes (see diagram).
Drill the two top holes on the lexan sheets using the 5/32" drill bit and the hand drill. Again, drill slowly and in short bursts.
Screw the lexan sheets and the 1" wood separators together with the #6-32 x 2" machine screws and nuts. Do the same for the bottom supports.

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