DIY assembly instructions

Assembly jig: a very simple jig is recommended to help hold frame sections in place while drilling and screwing. A fancy industrial machine is not required, our shop guys put this example together from materials available at almost any hardware store or lumber yard. All that matters is that it holds the corner secure, square and level.

Mitre cut the master frame extrusions to length. You need two for each height and two for each width. Use a cutting jig or material stop if possible so all pairs are cut to exactly the same size, there is very little play during assembly. When cutting, the spline channel must be cut to the inside of the angle.

Assemble one corner and one frame at a time. Do not pre-drill or pre-install corner inserts. Insert a corner insert into one end of a width cut, then install a height cut onto the opposite end to form a right angle.

Place the corner assembly into a holding jig, positioned so the corner is clean and tight. As shown, a fancy jig is not required. It simply must hold the frame square, level and tight.

Using a #26 drill bit, drill one hole at any of the four drilling positions. Drilling positions are centred on the drill line and positioned at 1-1/2" and 3-1/4" in from the outside edge on all corners.

Install one assembly screw into the drilled hole.

Using a #26 drill bit, drill one hole at either of the two drilling positions on the opposing side. Watch carefully, if your jig is loose the frame may "walk" during this operation and create a gap in the corner. Most assembly mistakes happen at this step.

Install one assembly screw in the drilled hole.

Using a #26 drill bit, drill the remaining two holes and install assembly screws. Ensure all four assembly screws are secure.

Remove the assembled corner from your jig and blow out all debris.

Place a corner insert into the shortest leg of your assembly.

Install the next leg of your frame onto the corner insert.

Secure this corner into your jig and follow exactly the same drilling and screwing procedure used on the first corner.

After two corners are assembled, insert the remaining two corner inserts into both ends of the final extrusion cut, then pre-assemble the frame by installing those inserts into the three-sided frame already built.

Drill and screw the remaining two corners using the same procedure. Repeat the whole process for each frame required.

Measure for proper length at the mounting location, this is the clear distance from shoulder to shoulder. Cut the divider extrusion to the exact size measured.

Cover the exposed face of the divider extrusion with painters tape before notching, to help prevent scratching.

Remove a 1/2" x 1/2" notch from each end of your cut. Material is removed from the spline side of the extrusion. This can be done with a properly outfitted table saw, milling machine, hack saw and so on.

Test fit your cut. Provided it is clean and square, the divider extrusion will fit snug and clean. If you need to reduce the length, remove only a slight amount at a time from one end only, cut the full length and re-notch. Repeat as needed for a snug fit.

Drill two holes at each end of the divider extrusion using the #27 drill bit. Holes are positioned 3/16" in from the cut end and 5/16" inward from the top and bottom. A simple drilling jig keeps every divider uniform.