Update - No.3 - 20.02.11

Originally sent to friends and family only in Feb 2011

As I mentioned in the last update, I made a scale foam-board model of the frames and baseboards just to see how things would go together and also to hopefully show any potential problems with the whole idea.  Once Mrs Corky had departed for work yesterday and I could put some prog-rock on the stereo (turned up to number 11 of course) and I could consume limitless quantities of tea, I referred to my sketches and plans and broke out the craft knives!  I've included a shot of my "work station" and the finished result.  I decided to make the scale baseboard sections 3' x 4' which will be the largest size used on the layout.  

Scale mock up component parts produced

Producing a scale model of the end frames

A scale model of a single baseboard section on 4 levels

You'll see the general principle.  It's along similar lines to a modern office desk with a metal frame supporting the desk and drawers.  I however will be using 18mm plywood in a single piece to act as a free-standing support for the baseboards.  The boards will be bolted to the frame and I will be able to work my way around the room by adding another end frame and baseboards as I go.  The only lingering doubt is whether plywood, albeit a thick sheet, can take the weight of the upper levels without sagging.  If it can, then I will be greedy and have 3' deep levels all around the room.  If they cannot, then I will cut back the upper levels to probably 2' and retain a 3' lower scenic level.  The baseboards themselves will be made from 9mm ply with an open grid construction with the trackbed supported on plywood risers.  More of the baseboards and their construction in a future update...bet you can't wait for that one eh?

Plenty of sketched ideas and notes before cutting any plywood

I took the scale model a step further and added another section to show how a corner could be dealt with....another couple of photos show this.  Having pondered on the model and the relative heights and depths of the levels I began to have some nagging doubts about the wisdom of the upper 2 levels being 3' deep.  Access, weight and banged heads made me wonder if this was entirely practical.  The only way to find out would be to actually create a full size pair of frames and do a mock up before I committed to the idea.  

Completed scale model of the corner arrangement

So that's what I did this morning.  I took the first sheet of plywood and marked it out for cutting with the original 3' depth on all levels.  The resulting frame was rigid and I knew immediately the idea was sound and I could build the "Corkscrew Lines" using it.   However, my doubts regarding a 3' depth to all levels were justified.   I took the jig-saw to the top 2 levels and suddenly everything seemed more rigid and access was vastly improved.  A major compromise from my ideal concept? - maybe, but one I can live with.  After all, I can still get plenty of railway in 2' and that's the 3rd level - I've got the first 2 levels to construct first before I worry about the 3rd!  

Cutting the first end frame section

First end frame section

Two end frames and a representative baseboard section - all working well

When I cut the next frame section I incorporated a few extra changes including a revised cutting plan for the lowest level to add even more rigidity.  This will reduce the number of possible storage tracks by a few but shouldn't make any difference really.  I will struggle to fill the storage roads with the amount of stock I have so no big deal really.  I was much happier with this 2nd end frame and stood it against the wall to simulate a representative section of the layout.  I placed a spare sheet of thin plywood on the 3rd level and it all started to make more sense.  See the photos for the various stages of the process.


 
I'm now faced with having to produce the first of the baseboards - logically this will be for the lowest storage level.  That means probably a couple of weeks of jig-saw and clamp action .... Ooh-Err Matron!  So things will probably be quiet for a while and I won't be pestering you.  Hopefully I'll be able to show you a completed section of framework and some baseboards next time.

Take care till next time my little "Corkettes", Corky!