I finally got back to assembling modules to work out a few issues I'd been having. The first was to adjust the size of the top module to make it easier to get into the sump closet. A few quick cuts on the table saw and now that piece is installed.
In my initial attempts at sitting these modules on the shelving brackets, I noticed that the surface of the module was not level. After some experimenting, I found that putting a couple of Masonite shims under the shelving bracket leveled the section up almost perfectly.
I was going to put a strip of material along the crosspiece, but after rethinking it a bit, these small squares of material are more than enough.
I also installed terminal strips on each module. The first module has one at either end. Subsequent modules will only have one strip, with the wires connecting from one module to the next.
These strips have enough terminals to account for multiple pairs of bus wires. At initial thought, there will be a track bus and an accessory bus. I may also add bus wires to connect lighting strips or building lights. Either way, I have enough space for future expansion.
October 21, 2017
The next step I took was to paint the Homasote a neutral earth-brown color. I was just going to paint the constructed modules, but I decided to paint all the Homasote I'd cut. It saves a few bucks on painting supplies (roller cover, paint tray). I would have gone on to the sky blue next, but I was out of space to put the painted pieces.
The paint dried very quickly, so I was able to stack some of the newly painted pieces on top of the pieces I'd painted earlier. Since this surface will be covered in track, roadbed, and other scenery, it's not necessary to have a perfect finish on the pieces, but I did my best. I used a 3/4" nap paint roller for the Homasote, since the Homasote has a somewhat uneven texture. It did a good job of filling in the nooks and crannies of the surfaces.
October 23, 2017
Next, I painted my backdrop. I used 1/4" Masonite (also known as tempered hardboard) because for a backdrop, it was far less flexible than the 1/8" item. The 1/8" should work well for fascias that need to curve, but these backdrops need to stay straight and I'd prefer not to put a bunch of extra lumber on it to reinforce it.
I painted 10 pieces of backdrop. These 10 pieces will last through upper level modules U1 - U3 and U5 - U9, plus the two lower level modules I built first. By the time I was done painting, the first piece was dry and could be attached to module U1.
I cut wire holes through the center of each crosspiece and mounted the module on the shelving brackets. I used some 1/8" Masonite shims to level the module at each shelving bracket. At long last, I have a finalized layout module on the wall.
After getting through this first module, module U2 should go just as easily. U3 will need to be cut to fit the space between the end of U2 and the wall, but I've got all the pieces to build it.
October 24, 2017
I installed module U2 but found that I did a lousy job on the shelving brackets. I ended up reinstalling 3 of them to level them up. After that, the module installed nicely. I leveled it with module U1, bolted it together, and secured the module to the shelving brackets.
After I completed that task, I was able to confirm the measurements for module U3, which goes between U2 and the wall to the sump pump / circuit breaker room. Using the painted backdrop and Homasote from the other day, I built and assembled the module. I used a slightly different support under the bracket due to the short width of the section. I need to adjust the backdrop a bit to line it up with the other section, but otherwise, it's just right for the space.
All in all, I'm happy with the result for the upper level. I've got a few things that I can do next:
- Build the structure in the sump / breaker room and cut tunnels through the wall. The lumber for this is out in the garage, so I'd like to get that done sooner than later since the weather is changing.
- Run the bus wires in each of the modules. I also need to install terminal blocks in the sump / breaker room to allow the wiring to go around the liftout sections. The wires will eventually terminate near the center of the east wall where the command station will be.
- Start laying down the staging yard track, starting with the throat closest to the sump / breaker room. I already have the basic design but need to update it to ensure it will fit the space.
October 31. 2017
Over the course of a week, I got the track laid in the upper staging yard, which covers modules U1-U3. Each of the tracks is at least 12' long, but the tracks get longer as you move towards the center of the yard. I started laying the track "horizontally" as seen in the photo below.
I had to keep moving my stool, so after the first few tracks, I started laying the track from the front to the back and it went much faster. While I didn't get the tracks perfectly straight, the slight deviations are only really visible because all the tracks are parallel. Each track is spaced 2" on center from the others, along with a wider space in front for safety reasons.
As I got the track laid down, I was able to determine how the yard throat would be laid out. In addition, I had some extra space towards the end and decided to put a small engine parking area there.
After I got the first few tracks down, I decided I needed to run some trains. Unfortunately, my feeder soldering skills were a bit weak on the first few tracks. However, the power flowed and I got the first trains to run successfully. The rear half of the yard went faster and I got all the pieces cut to finish out the throat.
I also finished up soldering the feeders to the bus wires, and then got the feeders connected to the bus wire using the suitcase connectors. Despite some people's statements to the contrary, I've had no issues with them at all.
The bus wires are wrapped around the terminal strips, but I am going to replace those with spade terminals to make a cleaner connection.
After getting all the wires connected, I was able to start filling the yard up with the fleet, after first rechecking couplers and installing metal wheels. Even though the trains are just going back and forth, it's still more operating layout than I've had in almost 20 years.
Next steps:
- Now that the tracks are cut, I need to drill holes under each of the yard turnouts to accommodate the Tortoise drives.
- I'll need to set up the accessory bus to power these Tortoise drives and try wiring up one of the turnouts to a local switch. I'll probably experiment with LEDs to show the turnout position, as well.
- In terms of construction, the next step is to punch through the sump pump / circuit breaker room wall and build the U4 section of track. Quickly thereafter, I'll start on modules U5 and U6 on the east wall.
