Building a Modular Style "Plug and Play" Layout

Building a Modular Style "Plug and Play" Layout

Special "Semi-Permanent" Modular Layout Design:

I am building a layout to be set up on one side of a two car garage. It will be designed as individual modules but they not intended to be compatible with or attached to train show setups or similar. My intent is to make everything "plug and play" so the layout can be easily set up and taken down or modified (enlarged) if necessary.

All wiring of the control system will also be designed as modules so that custom cables will be run between all control system modules and the layout.

The module height will be 60 inches above the floor. The modules will be supported by specially designed 2x4 legs attached with bolts, washers and wingnuts. The track will be laid on a special raised roadbed so that all track and signalling wiring will be self-contained (and hidden) within the roadbed structure. Wiring between modules will be via special connectors.

Note: The largest component of the layout will be the "WYE" section which is 72 inches by 36 inches. This means that I can easily transport the layout sections in my SUV if necessary.

The main focal point of the layout will be a WYE entrance to a center stub yard for use with passenger trains or intermodal freight. The outer loop will use O-72 track with O-72 turnouts throughout. An inner passing siding will use O-54 track.

Although the layout will be controlled by an MTH DCS it will also have conventional manual controls for selecting routes for use by visitors. This means that visitors can operate the turnouts using a combination of either pushbuttons on a control panel or separate MTH manual controllers.

For visitors I can run some of my "conventional" engines (such as my collection of Williams engines)using conventional control (bypassing the DCS completely).

6/26/1310:20 AM

❤️ 0

Original Post

Replies sorted oldest to newest

pro hobbyOGR Forum Member

Except for 2x4 legs all the lumber used is 1/4. Since I am buidling a semi-permanent layout I want to keep the weight of the frame as light as possible. The layout is designed to allow complete disassembly of the frame. I use bolts, washers and wingnuts and some wood screws for assembly. No glue, staples or nails are used anywhere. The layout will also be on casters so it can be moved easily but I also will have "stops" for when the layout is in final position.

6/26/133:20 PM

❤️ 0

pro hobbyOGR Forum Member

To keep the cost of materials as low as possible and design for the minimum of wasted material all the modules will use standard size lumber. For example the WYE track area uses O-72 track. This track area measures exactly 72 inches by 36 inches (track centerlines). This WYE section will be an individual module. The module will be built to exact dimension of 3 feet by 6 feet. However the fabricated roadbed will extend to a dimension of 38 inches by 6 feet.

6/26/133:32 PM

❤️ 0

pro hobbyOGR Forum Member

To provide additional rigidness for the 1 x 4 inch wood frames I will be using light chain and turnbuckles for bracing each module (installed criss-crossed). Once assembled the turnbuckles can be tightened as necessary. The use of chain and turnbuckles keeps the bulk and weight to a minimum while making the assemblies very sturdy.

As described elsewhere no wiring will be routed under the modules. However all the wiring will be hidden within the raised "roadbed".

6/26/133:46 PM

❤️ 0

pro hobbyOGR Forum Member

Since I will be building my layout as modules the "frame" for each major section will be assembled first then the "track" will be built using "open" construction. This means that I will not be adding a plywood base on the frame but will be constructing the roadbed separately and mounting to the frame. The roadbed will be made from 1/4 inch plywood and raised so that wiring can be hidden underneath.

For example the WYE module will be built on a 36 inch by 72 inch frame. However the diagram attached shows that the roadbed track for the WYE will extend to about 38 inches by 73-1/2 inches.

The adjoining modules will be bolted together using bolts, washers and wingnuts. Spacers will be added as necessary to each module to adjust for the actual dimensions of the roadbed.

Since I will be using MTH RealTrax I will ony need to add a "sub-roadbed" made from 1/4 inch plywood. The sub-roadbed will be designed similar to the attached prototype drawing.