I have just completed a scratched built structure and would like to post the assembly technique. I hope to start posting 'articles' like this every now and then. In addition to the posting below I have also attached a pdf file for anyone who would like to download.
In this article I will show how to build a custom designed freight station. The design is based on a previous build in which I assembled the basic framework and the customer completed the wall and roof lamination.
Ordinarily I would cut the end walls as one piece and use an Exacto blade to cut the roof line but because at one end the roof hangs over by 1 inch I chose to cut all ends plus the interior walls (support) as two piece units and glue together. The glues used were Plastruct Bondene for similar plastic (styrene to styrene) and Plastic Weld for dissimilar plastic to plastic. I used .080 (80 mil) styrene plastic for the walls and reinforced the inside for stability (warping). I used a table saw to ensure straight and consistent cuts on all pieces.
The holes for doors and windows were outlined in pencil then cut out using a plastic nibbler purchased from MircoMark. A 3/8 inch diameter hole was drilled first to allow tool access. Shown below are all exterior and interior walls placed in flat in position on the table then taped together.
Before gluing the walls together 3M Super 77 spray adhesive was used to laminate all exterior walls with Plastruct O scale 91551 clapboard siding. After the siding was applied The walls were glued together. Interior bracing was used to give more glue surface where the walls met.
Once the two sections were glued together a laminated piece of styrene was cut to fit the exposed portion of the wall where the two sections met.
Once all the walls were glued together it was time to add angle stock to the outside corners and roof bracing plus a some C-channel that would be used for lighting.
The roof was assembled next by cutting two separate pieces of 80 mil styrene. Thick styrene was used for stability since it will be simply painted and no roof lamination used. The roof panels were sanded with 80 grit paper to roughen them up. A small angle was also sanded on the edges were the panels met. To glue the panels together the building itself was used as a jig. The panels were placed into position, glue added to the seam and both held in place till the glue took hold. The nice thing about Plastruct Bondene is that since it melts the plastic it helps to make the seam disappear. However to make the roof look neater 30 mil flat strip stock was glued along the apex of the roof.
Next was the wood deck. I purchased 1/16 and ¼ inch flat stock cut out the platform and the supports. Wood glue was used to glue the supports and braces to the platform. 1/16 inch stock was used around the perimeter of the supports.
The building was fitted to the platform and 1/16 x 1/8 stock used on the exposed deck to simulate wood planks. The base was then painted black followed by Testors Railroad Tie Brown (not longer made). The long dock was made by gluing together two OGR docks and again painting Testors RR Tie Brown over black.
The roof was painted black and while the paint was still wet Woodland Scenics Cinder Ballast was sprinkled onto the paint. I let the paint dry overnight then sprayed it with Matt Medium and added more ballast where needed.
The windows again were painted black but over sprayed with Testors Roof Brown (no longer made). This combination gave a darker brown than using RR Tie Brown.
The main building was painted black followed by Rustoleum Camouflaged Khaki.
Interior lights were added then the windows installed. Except for some touch up paint the building is complete.
