Tag Archives: woodwork

‘Bedrock’

Part 4 of my railway modelling series. While the legless board was lying in the house following the events of part 3, a couple of shopping trips were made. On the first, I picked up a shiny new length of flexible track. The metal-cutters I had tried on an old length of broken flexible track produced very untidy results so, at the same time, I also bought a track-cutter to use on the new track.

Part of chipboard hill structure on model railway baseboard
Base layer: the structure of my hills begins to take shape
As well as ‘IT guy’ I am also ‘furniture assembler’ at work; the desks come packed with four strips of chipboard (roughly 2in by 1in cross-section) and I already had collected quite a few of these. At home, I had been given a small amount of chicken wire and Polyfiller, but this was not going to be enough to landscape my model. The aim of the second shopping trip was there to obtain materials for scenic development. I picked up some more plaster along with some PVA wood glue and cork tiles for laying under the track. I thought I would probably need some wallpaper paste too, so bought some of that as well.

A Step Up: Another level added to the hill structure (in the far corner)
A Step Up: Another level added to the hill structure (in the far corner)
Before commencing the messy work, I marked out the position of the track on the board, and rolled one of my longest items of rolling stock over the layout to mark the overhang on the curves. I then realised I wouldn’t be able to see these markings once I laid the cork. Fortunately, my grandmother had a bright idea; once I had lifted the track she produced a large amount of ‘tracing paper’ (I think it was actually baking parchment or greaseproof paper, given that it came on a roll in a cardboard box) and I copied the markings onto that.

Close-up photo of model hill structure, showing the scrap chipboard used in its construction
Recycled Material: Close up of the larger of the two hill sections, cobbled together from scrap chipboard
Going back to the track-lifting; this was necessary to avoid getting scenery-building material all over, and proved to be a challenge. Despite the fact I had left part of the track pins protruding, they took quite a bit of effort to pull out. When the pins eventually came up they did so suddenly and violently, taking the track with them and bending the fishplates joining the rails to the next (still fixed-down) piece of track. I hope only the fishplates are bent, not the track itself.

Chipboard hill structures on model railway baseboard
Chipboarding Complete: the basic structure of the hills, now complete
The bare baseboard was then taken back out to the shed and the legs re-attached. Over several days, I then constructed the underlying structure of the hills at one end of the baseboard using the free chipboard gathered from work. A lot of sawing and gluing was necessary, and I wasn’t able to get a lot done each day partly due to the limited length of daylight (there is no electricity in the shed) but mostly because I kept having to leave the glue to dry. Before I could glue the bottom layer of chipboard to the ply surface, I had to cut and fix the first small section of the cork base for the track (this can be seen in the photos, running through the cutting).

Looking down on the chipboard hill structure
Top View: the completed hill structure from above.
Finally, on 29th December, I completed the gluing of chipboard. On the 31st, I mixed up the left-over Polyfiller I had been given and made a start on trying to round-off the hills. More on the that will follow in the next instalment.

Modelling Foundations

Following the events chronicled in the first post on my model railway projects, I made a trip to our nearest Jewson store in search of a sheet of plywood and two lengths of 2-by-1 timber. Unfortunately they did not have birch ply, which my internet searches indicated was the recommended material for model railway baseboard surfaces. They did have sheets of ply the size I was after (2ft by 4ft) though so I purchased one along with the 2-by-1 timber which they cut into two lengths for me.

Back at home, work continued on the baseboard legs. I cannot remember the exact sequence of events, but each of the tasks undertaken will be covered here (just not necessarily in the correct order).

Photo of baseboard framework on legs
Unstable Table: my baseboard much as it would have appeared following the events of the previous post (except that the bolts holding the legs on weren’t installed then)
Somebody had found me some bolts to attach the legs, so four holes (one for each corner of the baseboard) were drilled to accept the bolts. As with the legs, the timer of the framework was rather hard; each hole took a while to drill and required a fair amount of pressure. The result of this was the drill would jump forward dramatically once it was finally through, hitting the internal bracing of the framework and causing me some alarm that the strength of the structure might be compromised. Fortunately the damage was minor and I was reassured that it was not a problem.

Close-up photograph of timber with a notch cut in it
Notched: one end of one of the two new brace timbers (the second timber, already installed, can be seen in the background)
After some measurements, I made a notch a short distance from each end of the two new lengths of 2-by-1 softwood timber. This was done by sawing roughly halfway through the timber and chiselling out the wood in between. The cutting was much easier than the old timber, and I doubt I would have been able to chisel it by hand as I did with the new stuff.
Close-up of baseboard leg brace timbers
Braced? Close-up of the two braces slotted into place on one of the legs (they aren’t fixed, to allow me to dismantle the structure)
These two lengths were then used to hold the base of the legs apart, with the notches slotting over the lower horizontal brace of the leg assemblies. At some point (probably before the notches were cut) it was noticed that these horizontals were not the same height above the ground, so one had to be moved to correct this so that the new spacers could work. Even now however, the table still wobbles slightly, though my idea of the new notched lengths of timber seems to help.

Photo of baseboard support structure (braced legs and framework)
Framework Supported: the near-complete baseboard, just waiting for the plywood top
I got out some track and had a play to make sure the layout I had in mind would fit. Interestingly, the arrangement I came up with was different from the plans I had created using layout planning software, so I recorded the plan (in the layout-planning program SCARM) before packing the track away.

The ply sheet was varnished, both sides, and measurements were made in an attempt to get the ply centred on the framework (the framework is slightly smaller than the ply sheet). Eventually it was pinned onto the framework using about 12 pins around the edges. I may have got the ply slightly off centre, despite all the measuring, but I’m happy enough.

Photo of bare baseboard outside shed
Outside The Shed: the ‘completed’ baseboard (now only slightly wobbly).

Scaling Down

It is a fact that I am a rather disorganised person. This blog is a good example of that, there’s no fixed time in my week allocated to ensuring that I regularly manage to publish posts. Thus, the blog can go months without a post, then have a run of posts at weekly intervals. That probably isn’t going to change, but my lack of organisation is not the sole reason for the irregular posting. There’s only a limited amount of content I can put out, and the stories I have are generally too lengthy to be completed in one sitting (so they get left in the drafts folder for months or even years). I’ve decided to try and resolve that second issue by broadening the scope of the blog.

Rather than just talking about real-life transport (and important but off-topic issues), starting with this post I will also cover my model-railway project(s). I have a dream to construct a rather large layout, but currently I have next to no space to set up a model railway. After many years hoping to find space, I have given up and decided to build something small and try to squeeze it in anywhere I can. This will also give me a chance to practice and improve my (currently very limited) modelling skills in order that, if I ever get onto my big project, I have a chance doing the idea justice.

Anyway, the starting point for this ‘something small’ is one of three baseboard frameworks of 2-by-1 timber made by my father for the layout I had in our previous house (the other two frameworks will remain in storage for the time being). I cannot find the legs the baseboards once stood on, maybe somebody used them to build something else. The first order of business therefore was to design and build some new legs. Design-wise, the big problem was how to attach them to the framework; initially I planned to have them hinge up under the board but it was pointed out to me that the bracing of the framework would get in the way of the screwdriver when I tried to attach the hinges. Outside hinges couldn’t be attached at one end, due to some damage on the timber, and they would have put the legs outside the framework. Back to the drawing board. I want the layout to be portable, meaning fixed legs are undesirable. With hinges ruled out, the new plan was detachable legs (held on by nuts and bolts).

Photo of damaged screwheads
Mangled Screwheads; they’re all too soft
Using some 2-by-1 timber found in our ‘random bits of wood’ storage area, a pair of legs (each formed of two verticals with two horizontals as bracing) were assembled over the weekend of 12-13th November 2016. The timber was very hard, sawing it to length was a pain and efforts to screw the components together were thwarted. The screws heads were too soft, with the slot for the screwdriver getting mangled (this happened both with brass-coloured screws and silver-coloured ones). After a few screws, the drill bit used for making the pilot holes snapped and screwing was abandoned in favour of nailing.

Parts of model railway baseboard in workshop
My baseboard legs and the framework leaning against the woodwork bench
Once the legs had been made, the structure was loose-assembled (we did not have bolts yet) and it was found the structure was not sufficiently stable; the framework would wiggle back and forth. Quite a disappointment, but I had an idea to solve it. The idea involved more 2-by-1 timber, and the remaining lengths from the stash I had found were not long enough.

That didn’t matter too much since I was intending to go wood-shopping anyway; the chipboard tops from the old layout have probably been thrown away, so some ply to form the new surface was on my shopping list. Progress would however have to wait until the shopping had been done.

So, I now have at least one follow-up post to write, but I don’t know yet whether this modelling series will run for very long.