A new layout in the making!

High Hopes

This page is to be updated as work progresses.

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Basic track plan.

The first steps was to obtain suitable timber (Planed Square Edge - PSE) and sheet boarding for the tops. For this project I am trying 11mm thick OSB3 board (Orientated Strand Board). Underside outer framing will be of 69mm x 18mm PSE and cross bracing at 300mm intervals made of 44mm x 21mm PSE. These will before fitting, have three 15mm dia. holes drilled in them nearer to their top edges. These holes will allow for later wiring runs.  The deeper outer framing will help protect the point motors and other underside electronic items and give good rigity and strength, while the smaller cross bracing timbers, when installed narrow edge to baseboard, give strength to the top but reduce overall weight. Fold up self contained legs will be added too.

The first frames and tops are constructed

15mm dia holes in cross bracing for later wiring

Fold up legs are constructed from 44mm x 21mm PSE and braced apart by two horizontal timber braces which are screwed and glued to the legs. Each leg has an adjustable foot and 200mm Tee hinges are used to act as the pivots.  Each leg is braced in the open position by a diagonal timber strut with Back Flap hinges at each end. See details below

To allow the fold up legs to be stored within the framing of each baseboard yet still allow the leg to be firmly locked in the down position 32mm Back Flap hinges are used at both ends of the strut. Each hinge has its original pivot pin removed and discarded and a split pin on a short length of chain is used to retain the struts firmly and securely. These make folding up the legs very quick and simple.

I have so far constructed five of the seven baseboards - Nos 3, 4, 5, 6 & 7 are ready for a coat of varnish or dilute PVA to seal them and then once dry I need to make room for the last two boards in the garage by moving them all forwards.

Baseboard top for board number 2 cut to allow for the upper level/raised section and the turn towards board 1. Next is to make the framing. But that will have to wait for a day or so now!

All seven baseboards have now been constructed and assembled to form the layouts rectangular shape. All surfaces have been sanded and then given a coat of dilute PVA adhesive to act as a general sealant.  Next track laying commences!

Next item to be tackled was the electrical connections baseboard to baseboard. For this I have opted for two different sized 'Aviation' plugs and sockets in four way pin/socket per connector.  I have chosen 16mm and 20mm diameter connectors, the larger being used for the DCC pair of feeds and 12volt DC power for all the electronic boards and Servo motor drives, while the smaller is used for CBUS data lines and two spare pins. By using two of differing sizes there is no chance of accidental cross connection occurring.  The Aviation sockets have a threaded protrusion on their front onto which the plugs securing ring locks the plug tightly onto the socket. The problem being if these sockets are mounted onto the front surface of the support framing timbers they extend out beyond the front edge and are then likely to be knocked or damaged during any later transportation of the layout.  So I decided to drill two holes for each socket and also allow finger room too for tightening and removal of the plugs. A hole of 32mm diameter was drilled for the 16mm socket while the 20mm socket has a 45mm diameter hole.  The sockets were mounted onto 6mm thick ply and that is bolted to the rear of the bracing timbers.

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Holes cut in framing pre cleaning up
Mounting plate
Mounting plate fitted
Plugs test fitted

Now commences the track laying!  I have a lot of Peco Streamline code 100 points taken up from the former 'Elmswood' layout and some sections of flexible track too, plus a new box of 25 lengths of SL-100 track. So this has to the choice, as it would be wasteful to go over to Code 75 profile track. In fact I've not had any issues with Code 100 looking too large, especially once its rail sides are painted rusty colour and the track ballasted.

Copperclad PCB used to hold rail ends at baseboard joints
Track laying begins
More track laying at one end of what will become the station throat
Points lead the tracks to the rear boards

Track laying is a slowly coming together and I'm now around 75% completed. I have today run out of 1.6mm thick Copperclad board which once cut into approximately 4mm wide strips is used for retaining the rails at baseboard joints. More is on order but I.m now at the mercy of the postal system! Track laying is slow as each piece of track has to have a pair of dropper wires soldered to the rails undersides before laying that section. Gaps in sleeper spacing will be made good before ballasting.

I have at long last completed 99.9% of all the track laying! Only ends of sidings to sort once buildings are purchased - Engine shed, Goods shed etc.

So onto the installation of the under baseboard wiring! 

Underside of one baseboard pending the installation of the DCC Bus pair of wires.  Droppers from the rails are Orange and Grey and the Blue wires are point frogs