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Chip, Our modular club recommends 3/4" paint-grade plywood be ripped to 4" for all major structural pieces of the modules. Legs are 2x2. Decking is minimum 2" extruded (pink or blue) styrofoam that sits on corner gussets. Modules bigger than 2x4 feet may have a cross-member, also cut from 3/4" ply. We used to recommend 1x4 (nominal) clear pine, but the plywood is more economical, stronger, easy to work with, and overall more stable. You can get the lumber yard to rip it for you - the cuts will come out straight if they use the big wall mounted saw (name escapes me...). Get it cut into 4" strips. You can do the gussets and anything else you might need with a table saw, mitre saw, or whatever you have at home. Andrew
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