Building semi-permanent benchwork

Building semi-permanent benchwork

Since I have only one side of a two car garage to set up a layout I have designed semi-permanent benchwork. This benchwork is assembled from 2x4 rails of various lengths which "bolt" to end sections of various widths. All bolts are 1/4 inch. The entire layout bolts together end to end to make up various configurations. I use RealTrax sectional track throughtout. The track is mounted on 3/8 inch plywood sections. To simplify construction there is no change in grade. Below is a description of my layout design for a 12 by 12 space.

Concept stub end yard with wye track used with MTH DCS control system.

This layout has a wye track leading to a small stub yard. The yard could be easily expanded by adding more sidings. The layout is designed as a "concept" layout which will be used to demonstrate innovative wiring and control techniques. The layout control will be used with an MTH DCS control system as well as a conventional Z4000 transformer system.

All turnouts are RealTrax O-72 including the Wye. All curves are RealTrax O-72 except the two sidings which use O-54 curves.

The benchwork uses sections which can be expanded by bolting on additional segments. The longest bench section is 6 feet. This could be extended to 8 feet or 10 feet by using a longer 2x4 section since every section bolts together using 1/4 inch bolts, nuts and washers.

I use MTH DCS and conventional control. I use both DCS remote control and conventional control using pushbutton and toggle switch panels for turnout and blocks. The control system is an integrated system that uses high current relays for control of turnouts and track blocks. The relays can be operated using the DCS AIU or separate pushbutton and toggle switch panels. The entire system is monitored by an LED indicator Dispatch Center.

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7/28/143:32 PM

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pro hobbyOGR Forum Member

Innovative approach to building a modular benchwork system

Here is an innovative approach to benchwork design using 2x4 lumber fastened together with hex head bolts. My concept layout is composed of various size modules that bolt together in various configurations. The layout height is set at 48 inches which places the track at near eye level. The modules are designed to be easily connected and reconfigurable since all pieces are color coded to make assembly foolproof.

My standard module sizes are 3 x 3 foot, 3 x 6 foot, 2 x 4 foot and 1.5 x 6 foot. All the modules bolt together to provide a very sturdy structure.

This system is NOT designed to be used with "show" modules since it is intended to be used only in a semi-permanent location. The use of modules allows changes and additions to be made to the layout design as necessary.

Note: The 2x4 rails could also be replaced and used to extend the module lengths to 8 feet or longer.

My modules are designed for use with O-72 and O-54 curves and turnouts.

Files (1)

TABLE CONSTRUCTION - WYE MODULE FRAMEWORK.pdf

7/28/144:13 PM

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PRR2818OGR Forum Member MEMORIALIZED MEMBER

How are the top 1x4's attached to the 1x4 & 2x4 leg? I cannot see it via your pictures.

Also, did you make up templates for determining where all the holes are drilled?

That way you could cut and drill all of the pieces and then just start assembling.

In the 2nd picture above, it looks as if the legs are not all square, is there not a need to have a bottom cross piece to ensure it is all square?

Also, are there any provisions for leveling legs?

I have seen in the past that even if my work is square and cut properly that the floor that I am placing it on may not be.

Thank you in advance!

7/29/149:45 AM

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Bobbie21921OGR Forum Member

According to the PDF plan he used #10 X 2 inch Flat Phillips Wood Screws for the 1 x 4 Cross braces.

looks like he used two Screws per side 1 into each 2x4 leg section

looks like a pretty good set up

7/29/1410:44 AM

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Former Member

My approach is similar to the photos above except I use pairs of 1 x 4's that are interleave cut and joined together at 90 degree angles. It's a lot of trouble to go to with dado cuts using a table saw but ideal for attaching angle brackets at the bottom with jack screws for leveling the table. Also, my layout is in a small room where dogs, kids, the wife and our linebacker cleaning lady can and do bump into it. When they do though it doesn't budge.

Can also post photos later if any interest.

7/29/1411:11 AM

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sinclairOGR Forum Member

So, how many times are you going to keep reposting this?

7/29/1411:24 AM

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PRR2818OGR Forum Member MEMORIALIZED MEMBER

Originally Posted by Scott T Johnson:

Can also post photos later if any interest.

If you could Scott, it would be appreciated, as I am getting ready to start construction soon and want to make sure I am doing this once!

7/29/1411:26 AM

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Former Member

Will do as soon as I get home this evening Dennis. Missed the part in your post about leveling. I have the same problem in my train room so I think you'll like the way the jacks work with the leg design.

Originally Posted by PRR2818:

Originally Posted by Scott T Johnson:

Can also post photos later if any interest.

If you could Scott, it would be appreciated, as I am getting ready to start construction soon and want to make sure I am doing this once!

7/29/1411:58 AM

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PRR2818OGR Forum Member MEMORIALIZED MEMBER

Thanks Scott!

Looks like I will be in your neck of the woods in October for our company workshop! I spent some of my formative years in the LA Area, 1963-1970, so it will be nice and scary to do some driving around to see how much things have changed.

7/29/1412:20 PM

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Former Member

Dennis,

As promised. Let me know if you need more detail.

Here's one of the legs. This is two 1x4's with offset 6" slots cut so the pieces fit together like gear teeth. You can see one of the 6 inch mating sections where the pencil lines are. After the cuts are finished I clamp the two pieces together and fasten with a nail gun. I make them a little longer than needed and do a final cut at each end with a miter saw. The finished leg is very stiff. Let me know if you need more detail on this.

The frame is choice cut redwood 2x4's and the legs are bolted on each side at the top similar to pro-hobby's posted photos.

One the leveling jacks at the bottom. A perfect fit between the pieces of the leg. Got these on line (Amazon) for $12 for a set of 4.

How level is the layout? Very. The overall layout is made of multiple pieces bolted to the original 3'x5' layout in the middle of my office. All of the pieces are as level as you see below. The top pieces are 3/4 inch maple laminate. The whole thing is total overkill from end to end but that's the way I like to do things. Also, as I posted earlier if you walk into the table, you move and it doesn't. The other payoff is amazing track sound quality. Something I didn't plan for but really enjoy.