It’s looking even better, George!
@Mark Boyce posted:It’s looking even better, George!
Thanks Mark. It seems unbelievable, but the last major bench work construction took place in 2018. After that, the focus was on scenery, river pouring, and bridge installation (completing in 2020). Then the Open Hearth took up the better part of 2.5 years. 
It's time to get rolling on building the rest of the layout. Once I've re-organized things (I lost a lot of open space), I'm hoping to ramp up track laying and Weirton Steel construction efforts.
If all goes according to my ambitious plan, Steubenville's bench work will be done before the end of 2024. No guts, no glory, right? 
George
Yes these extensive projects take a lot of time to do them right. You have really accomplished a lot looking back! I can imagine the reorganization that you will need to do to make for efficient model building!
@G3750 posted:Thanks Mark. It seems unbelievable, but the last major bench work construction took place in 2018. After that, the focus was on scenery, river pouring, and bridge installation (completing in 2020). Then the Open Hearth took up the better part of 2.5 years.
If all goes according to my ambitious plan, Steubenville's bench work will be done before the end of 2024. No guts, no glory, right?
George
I think the best part of the hobby for me is taking my time and doing it the way my mind's eye sees it. Sure, we probably spend more on materials redoing thing etc. But it never really gets done. That's the fun part. i just spent 3 months on a church. i bought it, modified it with many 3D prints, and redid so many parts. but now it's done and it was a blast! Thanks for sharing your journey. I enjoy the updates!
@LT1Poncho posted:I think the best part of the hobby for me is taking my time and doing it the way my mind's eye sees it. Sure, we probably spend more on materials redoing thing etc. But it never really gets done. That's the fun part. i just spent 3 months on a church. i bought it, modified it with many 3D prints, and redid so many parts. but now it's done and it was a blast! Thanks for sharing your journey. I enjoy the updates!
I agree. While I want to make progress rapidly, I have (so far) avoided the "just get trains running" syndrome that plagued me in building Panhandle 1. Of course, that was made much worse by building the layout in 30-45 minute time snippets stolen from fatherhood (I'm not complaining!), chores, work, and all of life's other demands. Plus my inexperience led to shortcuts that required rework or rebuilds of major chunks of the railroad. Panhandle 1 was a learning experience, and I have taken the lessons to heart. Now I'm all about making new mistakes.
Thank you for your kind words. I certainly am enjoying the journey but do want to drive that golden spike.
George
LT1Poncho and George, you both really said it all!!!!
Updated 10/25/2023:
Over the past few months, I've had some comments to the effect that the lighting in the train room was a bit dim. In fact, as I intensified my efforts on the Open Hearth, I noticed it as well. Both the train room and the workshop use the same lighting fixtures (track light pots) and 4100K color temperature LED bulbs. Back in 2018, I spent a lot of time researching the color and lighting options.
Today, I decided to do something about it. I pulled the trigger on an order for additional pots (same make & model) and more LED bulbs. In effect, I will end up doubling the number of pots in the train room and adding a few to the workshop. I also bought enough bulbs for these fixtures plus some replacements (because we know LEDs don't last as long as advertised 
).
Also, I am in the process of deciding where to position the buildings & kits I picked up at York (photo below).
More when I know it. 
George
Attachments
Images (1)
@LT1Poncho posted:I think the best part of the hobby for me is taking my time and doing it the way my mind's eye sees it. Sure, we probably spend more on materials redoing thing etc. But it never really gets done. That's the fun part. i just spent 3 months on a church. i bought it, modified it with Onmany 3D prints, and redid so many parts. but now it's done and it was a blast! Thanks for sharing your journey. I enjoy the updates!
One other thought about your comment regarding "sharing the journey". I think it's important to share the mistakes and missteps as well as the victories in this thread. In truth, the easy victories teach you very little; the losses have many lessons. Ignorance and inexperience both have cures. 
George
I agree, sharing the mistakes helps me think through the solutions, get ideas from others, and help others not make the same mistakes as they see what went wrong and how to recover.
Updated 10/28/2023:
Last few days have been spent lazily cleaning (I keep finding these piles of sawdust! ). But today I made a little progress by working on the access hatch and by installing a powerstrip under the layout. Initially, this will be used by the Open Hearth. It was a small job, but I ended up going to Home Depot, Harbor Freight, and Walmart for zip ties and other stuff.
Awhile ago I acquired some heavy-duty power strips. Mounting these upside down was a bit tricky. I reinforced the regular mounting hardware with zip ties to prevent accidents. This one is sitting below the Open Hearth, which is plugged in.
I ran the very long cord over to the layout's transformer table. Everything is powered ON/OFF by 1 switch.
More when I know it.
George
Attachments
Images (2)
George,
This a ingenuity at its best. I have a pop out in the corner of the layout that I was always concerned about. I have to lift it out, but then the problem is where to put it. This would help "open the gap" to that problem. I'm assuming that you just push the tubes up with your hands?
Dave
For whatever reason, I am having trouble getting this post back up after I pulled earlier this afternoon.
I will try again later.
George
OK, once more with feeling.
I want to thank Alex (Ingenerio No1) for his original idea of an access hatch that lifts straight up. I decided to install a large access hatch and support it with 2 lift mechanisms.
The following is his photo, which was originally published in another thread on this forum.
Some lessons learned from the effort:
- Aligning 2 lift mechanisms using wood blocks is difficult. One will be sufficient, especially if you prop up the other side of the hatch with a post.
- Just gluing the pipe into the wood may not supply enough grip. Think about drilling the hole all the way through the brace (as shown above) and using a set screw.
- A set screw drilling through wood may not be strong enough to hold the pipe. Home Depot sells screw inserts that can be drilled into the 2x4, tapped into place, and reinforced with JB Weld or epoxy. A thumbscrew can then be inserted in the screw insert to hold the pipe securely.
George
Attachments
Images (2)
Updated 11/1/2023:
Over the last couple of days the additional fixtures (track lights) and bulbs arrived. This morning I finally got all of them installed.
BEFORE
AFTER
Yes, it's more cluttered, but hopefully it's also a bit more brighter.
George
Attachments
Images (2)
George - Are you still planning on having the mill being a lift-out for transport purposes?
PD (healey36)
@pd posted:George - Are you still planning on having the mill being a lift-out for transport purposes?
PD (healey36)
Yes, I am but I don't plan on moving it very often (if at all). The mill has a tail wheel (underneath - it fits in a hole in the bench work) and removable handles. It can be maneuvered while on the layout. I plan to build a very shallow ramp or overlay that will fit over the track in front of it. That way, it can be pulled up and over the track without destroying anything.
The person tasked with moving it (I am not planning on being there) will have detailed instructions. He/she will need to bring 1 or 2 strong boys to carry that sucker up the steps.
George
Sorry, I know I've asked this before, but plans change sometimes. It sounds likes you've put quite a bit of thought into it, and in these recent photos, the scale of it becomes more apparent. It just looks massive, and with the new construction, it would seem a challenge to hoist it out of there.
Paul
@pd posted:Sorry, I know I've asked this before, but plans change sometimes. It sounds likes you've put quite a bit of thought into it, and in these recent photos, the scale of it becomes more apparent. It just looks massive, and with the new construction, it would seem a challenge to hoist it out of there.
Paul
Sometimes, I'm not sure I put enough thought into it. The mill IS massive. And it IS a challenge to hoist it out of there.
Actually, it's a challenge to get myself back there behind the mill (in the far corner where the divider meets the backdrop) to get some detail pieces back into it. My friend and I lifted the mill into position (I barely managed the lift); this was done with the cranes, ladles, scrap buggies, and ingot cars removed.
George
It's so exciting to see more benchwork coming up! I'm also looking to add a similar lift out section to my layout. The details you mentioned were indeed helpful.
What lights did you go with? I can't remember if I already asked.
@BillYo414 posted:It's so exciting to see more benchwork coming up! I'm also looking to add a similar lift out section to my layout. The details you mentioned were indeed helpful.
What lights did you go with? I can't remember if I already asked.
So the lights are track light pots by WAC Lighting. Model LTK-188-WT
Lights are 4100 K color temperature LED bulbs made by TCP. Part # LED12BR30D41K
I would also look into LED panel lights. I believe Amazon sells some 6000K LED panels (2'x2'? 2'x4'?). They would tend to throw more light and be less expensive.
George
Updated 11/10/2023:
Lately, I have been researching the prototype and planning for the construction of Crawford's Crossing, a highway overpass that carries Main Street in Weirton over the railroad tracks of the steel mill. It's named for the farmer that owned the land initially and preceded Weirton and the mill.
On the track plan below, Main Street begins in the lower left corner and travels to the upper right, terminating in the backdrop divider (thick vertical green line roughly 1/5 of the length of the layout measured from the right).
Main Street is partially elevated. The large light green block items are abutments (I show them sitting atop the road rather than hidden below it). Green, red, and blue strips that bisect the road are supports that will keep it elevated.
Here are a few photos of the prototype that I've taken over the years.
This one was taken about 10 years ago. The BOP (to the left) was still operating.
This is more recent. I had never seen the road without the mills that disguised it.
Pretty soon I will acquire the masonite (road surface) and other wood needed for construction.
More when I know it.
George
Attachments
Images (3)
Nice! I haven't seen that last photo before where here isnt anything to obscure the bridge. It's a great photo! Thanks for sharing!
A reminder about copyright guys!
@OGR posted:A reminder about copyright guys!
Thank you for the reminder, but we are on safe legal ground. I took those 2 photos in the 11/10/2023 post myself. And any photos of the mill I have published in this thread that are not my own are courtesy of the Weirton Area Museum and Cultural Center on whose board I sit and whose permission I have.
George
@G3750 posted:Thank you for the reminder, but we are on safe legal ground. I took those 2 photos in the 11/10/2023 post myself. And any photos of the mill I have published in this thread that are not my own are courtesy of the Weirton Area Museum and Cultural Center on whose board I sit and whose permission I have.
George
George...this was called to my attention. I appreciate your response however you MUST follow our TOS copyright policy which requires you to note that either you took the pictures and/or you have permission. Saying that you are using pictures "courtesy......" is not quite enough. Your more complete explanation above is perfect and had you explained it that way previously, your picture would not have been deleted. You are welcome to add your post with the picture again with the more complete explanation that you can use the Weirton picture due to your position on the board....that certainly will cover it! Thanks!
Updated 11/25/2023:
Lots of movement all along the Ardennes (where no one thought 3-rail could go! ). Here's what's shaking:
- After a couple of weeks of running around, I came to the final dimensions of the materials for the Crawford Crossing overpass. Neal Schorr (PRR Middle Division) was immensely helpful in this effort. The result will be much more prototypical. The search for the metal railings is still in progress; several promising options are still to be explored.
- Did an inventory of my remaining Vinylbed sub-roadbed in preparation for laying the track in the Weirton Steel Yard. It turns out that I had much less of the 3/8" high stuff than I needed. As a result, I pulled the trigger on 180' of the replacement stuff (thank you GunRunnerJohn!).
- With the Vinylbed I did have, I have begun laying track and subroadbed. This is the area just north and northeast of the curved switch (No. 16) and connecting to Switch No. 33). This is part of the Empties / Loads track.
More when I know it.
George
Attachments
Images (1)
Alright! Love to hear some track is being laid down. That's great news!
Updated 11/26/2023:
Spent part of today getting the Loads / Empties track and siding installed. These will hide inside the Blooming Mill. First up is the track plan showing the curved turnout entering the front of the Blooming Mill.
Next, we laid out the track that will pass through the Blooming Mill. In the background is the Open Hearth. Between the OH and the Blooming Mill is part of the Crawford Crossing overpass (flat on the benchwork).
Here are the two tracks and their curved turnout. There is a piece of Vinylbed that will be installed at the end of the spur. The spur has a short insulated section that will activate a light (might end up on a pole or the front of the Blooming Mill to let the operator know he/she has backed cars to the end of the spur.
Here's shot of the front of the Blooming Mill. It was always my intention to double the size of the door opening to accommodate the 2 tracks. Looks like its time to do the surgery.
Finally, here's a photo from a bit farther away showing the relationship of the buildings and the overpass.
Eventually, I will extend the track from the bottom of the curved turnout south to connect with the OH's pouring track.
More when I know it.
George
Attachments
Images (5)
Very neat trackwork George!
Dave
@luvindemtrains posted:Very neat trackwork George!
Dave
Thank you. Those curved turnouts are tricky. I've also found that I am not really a fan of the Vinylbed switch pads. I use them, they work, but they're just sort of there.
George
George, the track looks great as does the developing scene. I have never heard the term Blooming Mill before. What is it's function?
@Mark Boyce posted:George, the track looks great as does the developing scene. I have never heard the term Blooming Mill before. What is it's function?
Mark, thank you. To answer your question: A blooming mill receives ingots from an Open Hearth or Basic Oxygen Furnace and then rolls them into slabs, blooms or billets. This is an intermediate step that prepares the steel for further processing. A slab can be as big as 9' wide, while blooms can be 20" wide, and billets are up to 7" square. From the Blooming Mill, slabs can be sent to a hot or cold rolling mill (to make coils) while blooms and billets go to a structural mill (for extruding structural shapes or even piping).
George
George, thank you. Slabs and billets were terms familiar to me, though I didn't know about the difference in dimensions. I am well acquainted with the rolling mill. Now I'm up to speed...sort of.
@Mark Boyce posted:George, thank you. Slabs and billets were terms familiar to me, though I didn't know about the difference in dimensions. I am well acquainted with the rolling mill. Now I'm up to speed...sort of.
Mark,
This will really help: https://www.youtube.com/watch?v=VjN3fQWjRQQ
George
@G3750 posted:
Great video George.
But got to put my understanding in here. Back about 50 years ago when I lived in the Youngstown area and was the Quality Assurance Supervisor for a division of ITT that was heavily involve in designing and manufacturing of components for the Nuclear Power field our ASQC group toured one of the Youngstown Sheet and Tube Mills. The most interesting area was the Blooming Mill. Especially related inclusions and laminations seen in "finished" steel shapes and plates. First off the tops and bottoms of a teemed ingot have unwanted debris and inclusions in them at the ends. Now yes part of the blooming mills process was to roll the ingot into usable shapes to be further proceeded. But as seen in the video George pointed to you see where the ends of these slabs are cut off to remove these inclusions so they do not get rolled into the finished product. Now according to our YS&T tore guide this was know as the "blooming" operation. Which was most important that the operator cut off enough material so NO inclusions slipped through BUT not to much that good debris free Steel was lost.
Ron
@PRRronbh the piece lopped off at the ends was called a bloom butt. There was a bar on Walton Ave called the Bloom Butt Inn. The building still stands today.
Blooms/blooming is interesting because back in the day (before about 1800 I think) there was a furnace called a bloomery. It was used to make a bloom, which was a mix of iron and slag. It was better than straight iron ore but obviously not quite as good as what we would later get from a blast furnace. I don't know if the bloom went into a puddling furnace or what but the bloom was the original smelted iron. Given the way this industry works with traditions and old words (launder, salamander, dross, rosette, etc), I just assumed they reused the word since blooms were originally a mix of iron and slag; and then they went on to become pieces of steel with slag mixed in at the end of the piece.
Model and progress is looking good! It's exciting to see the real estate start to get filled up!
Thank you Mark, Ron, and Bill!
What a wealth of knowledge we have here on the forum. I am grateful for all the contributions and nuggets of information that help me make a more realistic representation. 
George
Updated 11/28/2023:
As you can see from previous posts and the initial photos (1 & 2 below), the first version of the Weirton Steel Blooming Mill had a door that was only wide enough to accommodate a single track. Photo #2 gives you a peek inside at the foamboard construction.
Some quick (and painless) surgery with a scissors and hobby knife created a wider door (photo #3). The trim, 1/4" styrene angle, was cut and notched to complete the work. Photo 4 shows the notching and Photo 5 shows the installed trim.
The next photo shows the Blooming Mill in its correct location relative to the Open Hearth in the foreground. It also shows me that I will need to put some sort of dark wall material just inside the Blooming Mill to hide the foamcore wall. The roadway lying in between the buildings is Crawford's Crossing. Of course, when the scene is completed, that road will be elevated about 6", further obscuring any look into that mill.
Finally, here's a closer view of the Blooming Mill and its new double track entrance.
More when I know it.
George
Attachments
Images (7)
Thank you, George for the video; and Ron and Bill for more description. I had the general idea once you defined blooming mill, but the video helped a lot. George, the model building looks great as it stands right now.
@Mark Boyce posted:Thank you, George for the video; and Ron and Bill for more description. I had the general idea once you defined blooming mill, but the video helped a lot. George, the model building looks great as it stands right now.
Thanks Mark. The Blooming Mill looks a bit foreshortened, but I think that impression will go away when the highway overpass, yard ground cover, and other details / scenery are installed. There's still a long way to go with that scene.
George
