Parts

Qty

Wooden parts

• Top bar

1

• Bottom bar

1

• Side bars

2

Wax Foundation

1

Pins

• Medium frame
• Deep frame, 3 holes
• Deep frame, 4 holes

 
4
6
8

Staples - 18 gauge, 7/32” wide, 1.5” long

2

Brad Nails - 18 gauge, 1” long

6

Tack Nails - 1/4 - 3/8" long

6

Step 1 - Remove the wedge bar

Top Bar for
wired wax
foundation

The first thing to do is remove the wedge from the top bar. You can note in the picture to the right that a small part of the wood is left holding it in place. The two parts are shown in the picture to the left: the top bar (blue), and the wedge (green). The gray block represents the blade cutting them apart.

The wedge (the green part) can be broken away from the top bar, or cut off using a knife. I prefer to use my table saw (with a very thin blade), and cut it off as noted in the picture to the left.

This approach provides a very clean surface on both pieces and does not require additional time to clean up the unwanted parts. The two parts need to mesh well to ensure the wax foundation is held in place well.

After getting the saw's rip fence set correctly, and the height of the saw blade, it is easy to cut many of these off in succession.

BE SURE TO KEEP YOUR BODY PARTS AWAY FROM THE SPINNING SAW BLADE. It is good to use a push stick and other safety devices when cutting these free.

Step 2 - Attach the side bars to the top bar

Staple Alignment
Side View

The steps are:

1. Ensure the side bars are aligned so that the eyelets are on the outside of the frame. It is not catastrophic if they are not, but moving the eyelets later is not a fun task.
2. Glue the top bar to the end bars. Be sure to glue the pieces together with all-weather glue (e.g., TiteBond III).
3. Staple or nail the parts together.
   • Add one staple, inserting it down through the top bar into the side bars. I prefer to use staples which are 18 gauge, 7/32” wide, and 1.5” long (e.g., Bostitch SX50311/2G).
   • If you use nails, two are recommended for each side.

Be sure the staples or nails go down thru the top bar and into the side bars. The picture to the right shows the proper angle for the staples to be added to the joint.

A frame assembly jig makes this quite easier, especially as it ensures the parts are kept aligned correctly.

Step 3 - Attach the side bars to the bottom bar

Nail alignment
Side view

Nail alignment
End view

The steps are:

1. Glue the bottom bar to the end bars. Again, be sure to glue the pieces together with all-weather glue.
2. Add two nails, one on either side of the slot. Staples are not recommended as they tend to crush the bottom bar. If you use an air nail gun, look for straight finish brads which are 18 gauge, 1” long (e.g., Bostitch BT1309B).

Be sure the nails go up thru the bottom bar and into the side bars. The pictures to the right shows the proper angle for the staples to be added to the joint.

Again, a frame assembly jig makes this quite easier, especially as it ensures the parts are kept aligned correctly.

Step 4 - Secure the top bar to the side bars

Nail alignment
Side view

The steps are:

1. Add one nail thru the side bars to the top bar. These are made from the side to help the top bar not come loose from the side bars when the frame is removed from the box. I prefer to use nails which are 18 gauge, 1” long (e.g., Bostitch BT1309B).

Step 5 - Drill larger holes for the pins

Using a 5/64” drill bit, re-drill the holes in the end bars. This will make the insertion of the pins easier.

Step 6 - Add the wax foundation

Frame with
foundation

The steps are:

1. Insert the wax foundation into the frame.
   1. The part where the wires are bent over at 90° goes to the top. They are shown in the picture to the right as the black lines between the top bar (blue) and the wedge bar (green).
   2. Start by inserting the foundation into the bottom bar (purple) and then leaning it into the top bar.
   3. Do not try to press the foundation into the horizontal wires.
2. Add three to five nails thru the wedge bar to secure it to the top bar. I prefer to use nails which are 18 gauge, 5/8” long (e.g., Bostitch BT1300B).

Step 7 - Secure the wax foundation into place using the pins

Using one pin for each hole in the end bar, press the pin into the hole with the head to the outside, and ensure the opening in the pin spans the wax: one side of the pin on each side of the wax.