First Sunday in June – 16mm scale layout

[WLR_CD]

Parts are starting to arrive, baseboard alignment dowels are now here.



While we source some quality plywood in the various sizes we require, I have taken the opportunity to test some of the production methods for board joining/aligning on some offcuts of ply I had kicking around.

The boards are to be aligned by location dowel plates, having never been impressed by, or succeeded with, the usual suggested installation methods, thought turned to devising a method that should ensure perfect installation and alignment each time.

The basic problem is wood and wood drill bits, they just cannot be aligned perfectly unless you jig up and clamp the timber perfectly.

The suggested spade drill bit is not the best either, far better to use a Forstner bit.

First up I clamped two facing end boards together and drilled right through them in two places with a 25mm Forstner bit, using a pillar drill to ensure an upright hole.



This leaves a nice clean hole which is a snug sliding fit for the dowel plate. This picture shows just one of the end boards.



The problem we now have is although the alignment is spot on, there is nowhere for the dowel plate screws to affix.

Solution is to route out a space for a block, roughly 40mm x 40mm to be glued in. To do this I first took an initial light cut from the back. Easier to do it this way rather than take out the whole depth in one go.



Then to set the final depth, drop in a dowel plate which has a thin shim underneath, this then gives a reference point to set the cutter depth to, which will eventually leave a hole that will take a dowel plate that will be set slightly below the end board surface. I put a dowel with the male part in because they are such a snug fit you need to grip the spigot to get it back out!



Now it is just a case of routing out to the full depth. I dropped the dowel plate back in to check fit, this is when I found out I needed to have a shim under the dowel. Not all lost on this one because it was simple enough to put this one back on the drill and just shave off a little more on the depth, the others were done with a shim.



Then 40mm x 40mm blocks of ply were glued in to fill the hole just routed.
Not pretty but I quickly chopped these up, left them overnight to dry.



Next day it was simply a case of dropping in the female plate, drilling a clearance hole though the middle using the plate as a guide. Then the plate was removed and the hole drilled out by a drill the next size up, this gives clearance for the location spigot as it passes through the plate into the timber. Finally drop in all plates and fix in place with the screws supplied.

I am pleased to say the end boards aligned perfectly.



Martin

[WLR_CD]

The first batch of plywood arrived, which we ordered as pre cut.



One of our team carried out site a survey, plotted all the levels and track route, from this information they made a full size master end board drawing, from this I was able to mark off all the measurements for cutting and machining.



First I made a master template to guide where to drill the dowel holes and cut the front main stretcher girder slot.



Time was taken to mark at an early stage each end board with a unique number so we do not get them mixed up, this was time well spent it made the cutting work a lot easier and confident the right piece was cut the right way round.



I set them out on the bench in order just prior to numbering.



For neatness, although this will not been seen once the boards base plates are fixed on, a template was made to guide the router to cut exact size holes. To do this a full scale drawing was made, printed out and used as a template for making the template.



First stage of routing was the dowel recesses and the main back board spline slot.



A bench saw was then set up to cut the track base support points on all the end boards. In pairs using the bench saw ensured they were parallel with the end board bottom edge. You can see in the picture the dowel backing plates have been stuck in place.



While I had made a mess and was covered in saw dust, a start was made on cutting some sleepers for track test building. I used a band saw for this, here doing the first cut.



A pile of sleepers awaiting the second cut.



Martin

[ge_rik]

A masterclass in precision woodworking.

Rik

[WLR_CD]

A masterclass in precision woodworking.

Rik

Thank you, I do enjoy woodworking.
Martin

[WLR_CD]

I started experimenting with different techniques to distress and weather the sleepers than I had previously used for a lighter weight track test piece did a while back for another layout.



This is based on my friends two foot gauge railway that uses large sleepers cut into three to make the track, with spiked rails.



Martin

[WLR_CD]

Rough overall track plan of the layout. Showing the six scenic boards and the RotaYard board. This changes at the RotaYard end further into the build.



Martin

[WLR_CD]

Bit more activity with machining timber ...



... and making baseboard/support locating toggles.



Using a jig and the template to drill the holes for the baseboard toggles mounting plate bolts. I used spare brass locating dowel plates to accurately locate the plywood template.



Then the holes were countersunk, just got to get the bolts now.



First stages of assembly of baseboard number one. This took place on an old kitchen worktop, under which we bolted a length of 6 x 2 steel tube to make sure the worktop was perfectly flat. With baseboard building, the more accurate you can get it at the start, saves a whole load of heart ache later on!



Glueing up the front lower beam, you can never have too many clamps!



Martin

[WLR_CD]

Nothing happened on the layout build for nearly a year!
The day job became very busy, I built a second shed and bought a classic car to restore, the layout build was therefore put on hold.

Corner pockets are constructed on each board. These are for hand space while using the board toggles.



Inner timbers for the board supports were all cut and drilled in one session.



These were glued up with the 3mm ply outer skins in two batches, mainly because we did not have enough clamps that are big enough to do them all at once.



Martin

[WLR_CD]

A few ribs at the front of board one now installed.



Now onto the supporting legs and how they connect up.

The aim is to avoid any use of bolts with the erection of the layout:
1) avoid the possibility of forgetting the bolts.
2) speed of put up and take down.

The rear cross braces for the legs are steel strip, held to the boards with these toggles, very similar to what can be found holding up trailer and pick up sides and end doors.



The first problem we came across was the hole required in the strip to clear the toggle element was obviously larger than the toggle support screwed into the legs. This resulted in a slightly sloppy fit, which basically worked but we wanted something that was rock solid.

The solution was to turn some collars, which as you can see in the photo above gives a very snug fit for the bracing strip. The collars are deep enough to accommodate two layers of bracing strip, we machined a chamfered edge to aid guiding on the bracing strips.





This is the first time we tested the theory, the clamp is there purely to see how rigid it ultimately could be and because at this point the front bracing strips had not been thought about or indeed considered.



To test further we tried out a number of legs, at this point it became apparent the addition a front brace would be preferable, although not necessary when the baseboards are attached. But it does mean we can assemble all the legs and move them as a whole should that be needed while installing the layout at a show. We have all been there, erected the layout and the organiser comes along and says can you move a few feet left!



We came up with a whole range of wonderful solutions for the front brace, but many cups of tea later we revised it down to a strip of steel and a screw. So front braces were fabricated from the same steel stock and suitable locating holes machined out. These are now simply dropped in place on the screws.



The bracing strips have a dual purpose, when not bracing the layout they are clipped together and form trolly handles for the sandwiched together baseboard legs, which with the simple addition of a plate and trolley wheels mean no lifting required.

Here you can see the first two boards assembled and tested on the legs. Also the curved under sheets can be seen.



Martin

[WLR_CD]

To update, marking out the track on the first few baseboards.





Many clamps make light work, here glueing the blocks for the over latch clips on board 3.



Board 4 is now beginning to take shape.







Boards 3 and 4 progressing, slower than I would have liked, the drop in temperature has certainly slowed down the gluing setting time and the thought of bringing it indoors to dry in the dining room did not meet with approval!



Martin

[WLR_CD]

An evening session consisted of erecting four boards, 1,2, 3 and 4, this gave us the opportunity to plot the track routes through boards 3 and 4 so the track subbed can be constructed and the boards finalised as far as timber work is concerned.

We were extremely pleased at how quick the supporting leg work assembled and the accuracy to which the boards aligned and clipped together without any adjustment being required. Board 3 is the one where the main line falls away so a gradient is introduced which carries on through boards 4 and 5, where it will level out before board 6 from where it will enter the fiddle yard.

View from board 1 end.



View from board 4 end.

The trackbed on the right of board 4 is not the correct piece, it was a temporary board to support the ruling strip we were using at the time, the actual board angles more to right to where the goods shed will be located and stops short of board 5.



Boards five of six now has the basic elements assembled.



This is the underside of two of the boards showing the channel that runs the entire length at the front of the boards.

The well in the furthest board is for access to the underside of where the points will be, when complete a removable panel will be fitted here.



This photo shows boards three, four, five and six. We are plotting the curve of the main line so that board six can be constructed.



This shows the changing track levels on boards three and four.



Here we are mocking up positioning for the facia and thinking about the supports for this.



The first prototype facia supports tested.



With these in place, LED light panels were trialed as a potential light source, early impressions are very encouraging.



Martin

[WLR_CD]

In a period of fine weather, it was opportune to connect up all the scenic boards and parts there of to get a feel for the size of the layout.

In the pictures below, the ruler laid on the boards is a one foot rule and placed roughly where the end of Stony Shaw platform and foot crossing will be. Yet to be added is the eight foot of baseboard for the RotaYard at the far end of the layout.







Track bed on board five is now installed.



Construction of board six, the final scenic board has started. The end panel is roughed out, we have not decided on the final profile yet. The triangle of plywood is a temporary brace as the board is built. Clamped while the glue dries are the side supports for the front beam. Once dry, the base will be cut out and a top fitted.



Despite all the planning, sometimes one of these comes in very useful during construction!



Martin

[WLR_CD]

Now the scenic boards are well underway, attention has been paid to the RotaYard.

This is one of the early concept models.



A CAD model has been worked up to prove the functionality of the concept. There are six stock Gondolas, the system has been designed to cope with all six full up with stock.



One gondola in isolation, the red block represents one full length train.



One of the Gondola support brackets.



A fully loaded RotaYard.



Martin

[WLR_CD]

Baseboard construction continues and ground form starts to make an appearance.

Final piece of scenic section trackbed now installed, four of the six scenic boards are in this photograph.



Using a lot of this stuff to stick down the foam.



Gorilla glue expands to three to four times its size and also acts as a filler that can be carved, sanded and painted. Sticks like the proverbial to a blanket!



What you must remember to do is make sure location dowel holes are covered at the rear!



Some of the boards with foam waiting to be stuck down.



Trunking for the wiring is also installed along with aluminium tube to hold the point rodding.



Very therapeutic shaping this with a Surform, makes it very easy, sometimes too easy.



CAD of the RotaYard main support frame.





This has now been welded up and ready to be used as a guide when building the plywood baseboards in which it will sit.



The RotaYard gondola supports are out being CNC'd. Plywood for the RotaYard support baseboards has been machined and now awaits assembly.

All of our patterns for the track plates have been cast and the brass castings have arrived. The rail which we imported from the USA has also arrived. I will go into detail about the track later.

Cutting sleepers is the next task, then we can start sticking these in place and build the track.

Martin

[WLR_CD]

A bit about the trackwork for this layout.

The concept for the track is:

Follow the prototype as closely as possible,
No visible wire connections
High detail level
Provide reliable running ​
We had a search around for rail, and found that Tenmille produce a flat bottom rail which is suitable.

Working from the full size fixings we produced a selection of base plates from .9 nickel silver plate and half round rod to simulate the elastic rail fixing point.



The first two plates didn't quite fit the size as the half round rod is from a well known supplier, and not of the correct size.

The one in the photo is about right, this used a half round section machined from a 3/32 bar which is to scale size.

The elastic fixings need a bit more work to lengthen them slightly, using a simple bending jig which is easily modified.



An interesting side-by-side comparison shot, just a few little tweaks to do and we are almost there.



Martin

[WLR_CD]

Track fixing component master patterns for casting were made.

Pandrol clips.



Point slider chair plates.

[

Base plates.



Base plate bolts.



Fishplates front and back.



Eventually we ended up with bags of lost wax castings.



Lots of sprue cutting to do now.



Martin

[WLR_CD]

The final scenic board now has the foam cut ready to be glued in place.



The prototype gondola support bracket has been CNC milled from plywood and has passed all weight and stress tests.



Here shown with some stock in place to show clearances.





Now we can go ahead with production of the twelve supports and construct the RotaYard.

Martin

[WLR_CD]

Construction has at last started on the final two boards of the layout, these are the ones that will be supporting the RotaYard.

The mid-joint cross pieces get quite thin at one point, this has been compensated for by beefing up some of the other surrounding structure materials.

This is a mid-joint cross member with all the machining done.



One element beefed up is the 3mm ply sides for the front channel, these have been upgraded to 12mm square softwood.



Then topped off with 12mm ply rather than 3mm ply.



This did involve some thinking on how to get it all clamped while the glue dried!



Now the scenic boards have the foam in place and carved to shape, some form of safer storage was needed, so to this end some old bits of Dexion came in handy to make a supporting frame for the boards.



Now the basic structure has been made for the RotaYard support boards, more detailed construction can take place using the main metal frame as a guide to where all the elements should go.



We will be welding on some adapted Spur shelving brackets for the main uprights.



Here you can see the beefed up front beam of the baseboard which supports the frame full length, some softwood timber will be machined to support the full length of the rear frame. Also the CAD of the RotaYard can be seen on the laptop, which we use not only to create working drawings for the construction but also to check it will work and all clearances are sufficient.



Martin

[WLR_CD]

Lots of cutting and machining of timber has taken place to get 350+ sleepers.



Plus a few longer ones for certain parts of the points and switch lever mountings.



After a lot of this cutting you get a little bored and do daft things!



Those sleepers that did not make the grade were not wasted, they were used to test the strength of the glue we intend to use and have something to develop the painting and ballasting techniques.

Thin beads of Titebond III was first applied to a piece of scrap ply.



Sleepers were pushed into this, weights laid on top and left overnight to dry.



Next day they were attacked with a wire brush and pleased to say they all firmly stayed put.

Then some initial colouring trials were started, these pictures are of a very early stage in the colouring process.





Martin

[WLR_CD]

Now the RotaYard.

The main construction welding is now complete and the main drive shaft bearings have been sourced.





An overall view of the RotaYard in position on the two supporting baseboards.



The main drive shaft should be machined to size tomorrow if all goes to plan.

Focus turned to the end disks which support the gondolas and provide the drive to them.

This is the Mark I end plate.





Aesthetically this was not ticking the boxes for us, especially for something that will be so visible. Back to the keyboard and revise the design.

Welcome Mark II.





This one is a lot better, having been run and 'proved' in the CAD simulation, the files were sent away for water cutting in aluminium.

A few days later a package with two disks arrived. We mocked them up with a broom handle acting as a temporary drive shaft to support them.





The gears for the drive on this are due to be delivered soon.

Here is an overall view, on the gondola are full size 16mm CAD drawings of the stock of the longest train we will be running on the layout.



To give some idea of the size of the RotaYard, I placed a 7mm standard gauge wagon on the gondola.



Once stock leaves the final scenic board it will pass onto the RotaYard support boards where before entering the RotaYard it will cross a loco size traverser. To support and guide the traverser we bought some linear bearings and guide bars, they are very free moving so will need very little power to move them.



These are actually shown upside down and not at the correct height or position.



Martin