PRR Panhandle 2.0

Updated 6/1/2018:

We're still at Step 6 (the tricky part). Here is the first upright for the divider. It's clamped in place.

Here's a slightly closer look at the first upright.  The most important thing for these uprights is that they are vertically straight, relative to the backdrop than anything else.  Within the plane of the backdrop they can be crooked, I don't care.

Here's the 2nd upright.

I used a long screw and a corner reinforcement to make sure the second upright stayed in place.

I also remembered that I have to bolt the two tables together and create holes for wiring runs.

Q: How do you know you’re making progress converting a pile of lumber into a layout?

A: You start hitting your head on the bench work above.  

More when I know it.  

George

G3750 posted:

Updated 6/1/2018:

 

Q: How do you know you’re making progress converting a pile of lumber into a layout?

A: You start hitting your head on the bench work above.  

 

More when I know it.  

George

George,

  Maybe we should all pitch in and by you a hard hat!  

  Nice progress.

Tom 

MNCW posted:

G3750 posted:

Updated 6/1/2018:

 

Q: How do you know you’re making progress converting a pile of lumber into a layout?

A: You start hitting your head on the bench work above.  

 

More when I know it.  

George

George,

  Maybe we should all pitch in and by you a hard hat!  

  Nice progress.

Tom 

Thanks Tom!  I am pleased with the progress over this week.  We're starting to pick up some momentum.

George

Thank you, George!  Yes you got it right!  Looks great !

Mark Boyce posted:

Thank you, George!  Yes you got it right!  Looks great !

Thanks Mark!  

George

Updated 6/02/2018:

The progress on the backdrop divider continues!  The next few photos show the installation of 5 of the 6 vertical supports.  That's a piece of masonite backdrop support in the left foreground.

To get the 3 pieces of masonite to fit, I had to be very careful with the placement of the vertical supports.  Masonite widths (from wall to aisle) are 4', 2', and 4' for a total length of 10'.  The vertical 2x2's must support the points where the masonite pieces abut.

In this tight space, corner braces were the right choice.

Here we've got 5 vertical supports in place.

Here's a photo from behind the backdrop.  I'm wedged in the far corner.

The framework for the next table is propped up on the blue bins awaiting assembly.

We even had an inspection visit from Samantha.  Her boss, Chief Motor Inspector Pumpkin is too arthritic to get down the stairs.  So she sent her underling instead.

George

George, the backdrop supports and tables look great!!  You are moving in the right direction!

Well I'm glad Pumpkin has an understudy to keep an eye on this project!  Samantha will be reporting in if you take any shortcuts!  

I'm counting on Samantha to keep me from taking shortcuts!    

Of course, I do have to keep her from eating sawdust.    If she does, we'll see it later, unfortunately.  

Yeah, I'm trying real hard to not take short-cuts.  There is a plan and there is no rush to get trains running (way too far off in the future).  So far, I feel like I've been careful.  I've stopped and re-thought a number of activities, preventing mistakes.  I feel pretty good about the construction to this point.

George

Oh yes, eating sawdust.  I can believe that!  Could be a problem on cleanup.

I believe this is one of the most well thought out layout builds I have seen!  The plan is quite impressive; yet to do what you want to do with the steel facility, you need to have a good plan.  Yes rushing it now could squander all the good planning you have done!  I'm glad you are keeping us up to date!

Mark Boyce posted:

Oh yes, eating sawdust.  I can believe that!  Could be a problem on cleanup.

I believe this is one of the most well thought out layout builds I have seen!  The plan is quite impressive; yet to do what you want to do with the steel facility, you need to have a good plan.  Yes rushing it now could squander all the good planning you have done!  I'm glad you are keeping us up to date!

Thank you, Mark.  That is very kind.

George

Updated 6/03/2018:

After church I managed to assemble most of the 2' x 8' table nearest the aisle (surface #4 on the diagram). I still have a cross member to add and a vertical upright for the divider. After that, I will install the divider and most of the Staging Area will get its plywood subroadbed.

Here are some photos. This first one shows the table on its back with the legs being attached.

I clamped the new table to the others in the Staging Area. This table's legs differ in several ways from the others.

• They are outside legs and will be more visible than the others.
• Because they are more visible, I used poplar so as to improve their looks. I also stained them a slightly darker color than the others (not sure it shows up).
• Because of imperfections in the floor, these legs are 1/4" shorter than the others. I am also using a slightly wider leveling glide.

Here's a closer view of the table. A cross member will be installed to support the final vertical backdrop column. The vertical 2x2 will go at the extreme right hand side of the table.

OK, more when I know it.  

George

Updated 6/4/2018:

Well, things are on hold.  The doctor found 3 more retina tears and repaired them.  No layout work for a few days.  

George

Oh no!  I am sorry that happened!  Thinking of our discussions last fall, I'm sure you will do everything the doctor told you to do.

George,

  Good luck with your health issues.

 Tom 

Updated 6/5/2018:

Yesterday I did play around with my Lionel Industrial Smokestacks for my Open Hearth.  I've cannibalized 2 stacks (taken the middle section) and extended 2 others with them.

That left me with 2 "shorty" smokestacks (I have only shown the one;  the other needs some repairs).  Anyway, I wired up 3 of them.

George

Looks great!!

G3750 posted:

Updated 6/4/2018:

Well, things are on hold.  The doctor found 3 more retina tears and repaired them.  No layout work for a few days.  

George

George.....best wishes for a speedy recovery!

Peter

Mark, Tom, Peter:

Thanks.  I know what I need to do and I'm doing it, so maybe on Monday I'll get the OK.

In the meantime, baby steps.

George

Looking good George. I do agree with the hitting of the head equalling progress. Always have had that happen no matter what.

Updated 6/12/2018:

Well, the doctor gave my retina a clean bill of health - no tears!!!!      So construction has resumed!

First, I am about 75% through the task of identifying and counting the remaining number and types (measurements) of 2 x 2's that I will need to complete the benchwork. When I've double checked this number, I will place the order and have them delivered. These will need to be shellaced.

Today's work was about attaching the remaining table to the wall and to its neighbors.

I can't recall where I read about this technique.  I want to drill clean holes through the 2 ribs that form adjacent tables. If you clamp another board to them and then drill, you get a clean hole. 

Here's the clean hole!

I am using a 4" carriage bolt, 2 fender washers, a lock washer, and a nut to hold tables together.

Here are the two tables bolted together.

I am also taking care to drill holes in the ribs to accept wiring.  That will be harder to do with the table tops installed.

Finally, I attached the table to the end wall with 3" drywall screws.

Hopefully, more tomorrow!  

George

George, That is great news about the retina!!  

My dad taught me that trick to use scrap lumber to get a clean hole.  The only power tool he had when I was growing up was an old power drill.  I like your method of bolting the sections together.  That would work great for a home modular layout that the only intent is to take the modules apart if you had to move or a very rare change of modules.  I'm glad you are back at work on the benchwork again! 

Mark Boyce posted:

George, That is great news about the retina!!  

My dad taught me that trick to use scrap lumber to get a clean hole.  The only power tool he had when I was growing up was an old power drill.  I like your method of bolting the sections together.  That would work great for a home modular layout that the only intent is to take the modules apart if you had to move or a very rare change of modules.  I'm glad you are back at work on the benchwork again! 

Yeah, I am very happy and relieved about the retina settling down.

It's no surprise that the clean hole technique is old, probably well over a hundred years old I would guess.

I've learned that there really is no practical way to build a permanent layout in pieces that can be separated or transported.  You either have to go totally modular, i.e. designed that way or not.  This particular method using carriage bolts is what I used for Panhandle 1.0.  I really didn't give much thought to another approach.  It works.

The innovation (if we can call something that simple by that term) is to drill wiring holes between tables before installing the plywood table top.  I'm expecting that to aid greatly in running wires and keeping the under table clutter to a minimum.

I am trying to be very deliberate in my planning and construction techniques with this layout.  Panhandle 1.0 was built in short 30 and 60 minute slices stolen from the relentless demands of work, family life, and kids.  It was the product of hasty decisions, impatience, and improvisation - often with undesirable outcomes.  Conditions are different now, and I expect the outcome to be much, much better.

George

Like they always say, "you are never told old to learn." One thing if for sure, no matter how you plan, sometimes there is always something that stops you dead for a bit until you work out the kinks. Its always something. Good to hear things are going smooth with your planning, and glad the retina is better.

Dave, I have been to George's house, and I don't think the original Panhandle Engineers planned it out as much as George has.  What he has on computer and in print is outstanding!  My guess is, there will be small tweeks on Panhandle 2, where you and I may have scrapped whole sections to redo.  

Mark Boyce posted:

Dave, I have been to George's house, and I don't think the original Panhandle Engineers planned it out as much as George has.  What he has on computer and in print is outstanding!  My guess is, there will be small tweeks on Panhandle 2, where you and I may have scrapped whole sections to redo.  

You are too kind.

George

Updated 6/14/2018:

• Added another 4 holes for wires to the benchwork.
• Completed the list of 2x2's
• Attached the benchwork to the walls.
• Re-evaluated the benchwork drawing against the layout.

George

Updated 7/3/2018:

It's been a while since I reported any progress.  That's because there hasn't been any.  Instead I discovered a couple of problems that I am closing to fixing.

1) I misread my plan for the Staging Area and built a table that is a bit too wide. I will cut that to size and re-install shortly.
2) I realized the backdrop that goes on the long wall is 2' 9" too short. I am working on a solution with the backdrop maker.

Neither of these errors are anything but speed bumps.  

George

Updated 7/5/2018:

Made some serious progress yesterday and today. I cut 3.5” lengthwise off a table that was too wide and moved that up against the uprights for the divider. That piece will hold a track that enters and exits the Staging Area, allowing empties to be exchanged for loads (and vice versa). I made the appropriate changes to the track plan to allow for this modification.

I also cut a notch in surface No. 5 and fit it into place. This involved making two parallel cuts and then using a drill and keyhole saw to complete the hole. I then squared up the hole with a Dremel cut-off wheel and grinding tool.

I placed the order for the rest of the lumber today as well.   

Pretty good progress, if I do say so myself.  

George

Looks great!

Mark Boyce posted:

Looks great!

Thanks Mark.  I think we are back on track now.

George

Updated 7/6/2018:

I notched and test fitted Table #5. It is too wide and must be cut to the proper width. Therefore, I have left it and Table #6 lying in place as spacers (not fastened down). See photos.

These tables are temporarily acting as spacers for the divider sections (1/4” masonite) that must be installed above them. In the photo you can see one of the 3 masonite divider sections leaning against the vertical 2x2”. I’m using carpenter shims to help place the divider sections. The photo shows all the pieces just before test-fitting. I’ve got to move the 2 track lights and notch the top right section of the masonite to clear the lighting track.

The debate I have been having with myself revolves around cutting openings for the hidden reversal tracks and entry/exit tracks for the Staging Area. I could try to cut the openings in the divider before I put it in place. Unfortunately, my ability to accurately place these openings is appallingly similar to my success picking winning lottery numbers or horses. In other words, it sucks. Therefore, I am going to install the dividers, lay down the sub-roadbed and track, move it around until I’m happy with the geometry, and then fasten it down. After that, I will know where the reversal track entries / exits and the Staging Area portals should go. A plunge type cutting tool like the Saw Max followed up by a saber saw should do the trick. This approach should work, especially if I pull away Table #5 to get another 5/8” of vertical clearance for the cutting tools.

Here's the first of three masonite panels that form the divider. It is partially installed.

Because of some inaccuracy on my part or the warping of this 2"x2", I don't have enough of the vertical support to anchor the adjoining masonite panel. The answer is to install another 2" x 2" next to this one.

That's it for now.  

George

I agree, I would have to mount the Masonite, then determine exactly where to cut for the tracks to go through.  Also, I have the same kinds of problems where something doesn't line up.  Good solution; splice on another 2x2 where needed.

Updated 7/7/2018:

Added the extra 2"x 2" vertical support for the divider.

Also fastened the first section of the divider to the vertical supports. 

Also fastened the first section of the divider to the vertical supports. 

Spoke with the backdrop vendor. He is going to correct the problem. Our task over the next few days is to test-hang the backdrop and make sure that there are no other discrepancies.

George

Great progress! I like this idea of the backdrop to obscure the reverse loop and separate the scene from the rest of the layout. 

One thing I did notice while reading your post - this photo illustrates the issue. You’ll have to slide the bottom out to remove the backdrop and if the roadbed and tracks are in the way you might have trouble removing it. You may already have a solution but just double checking!

atanz posted:

Great progress! I like this idea of the backdrop to obscure the reverse loop and separate the scene from the rest of the layout. 

One thing I did notice while reading your post - this photo illustrates the issue. You’ll have to slide the bottom out to remove the backdrop and if the roadbed and tracks are in the way you might have trouble removing it. You may already have a solution but just double checking!

Alan,

Thank you for your concern!  Maybe I didn't properly understand your point, but the backdrop isn't meant to be moved once it is installed.  Once in, it stays put.   Sequence of assembly is:

1. Install the masonite backdrop walls (as seen above).
2. Remove the table surface (it is not fastened down).  Right now, it's acting as a spacer.
3. Cut the table surface to the proper width; it needs to fit the table framework underneath.
4. Reinstall the table surface permanently.
5. Prep the masonite for the backdrop.
6. Install the backdrop on the masonite.
7. At track-laying time, finalize the location of all tracks that will pass through the backdrop.  Use a Dremel Saw Max or other plunge-cutting tool to make the correct holes in the backdrop at the appropriate spots.  There will be at least 4 holes.

Hopefully, I addressed your point?

Please keep posting your thoughts and suggestions.  That's very valuable to me.  Even explaining something I think I'm sure of, makes me revisit and confirm my approach.  Very valuable!

Best,

George

Ah yes! I misinterpreted your point of cutting the hole in the backdrop. I thought you would have to remove it to cut the hole, but the Dremel solution works just as well!

atanz posted:

Ah yes! I misinterpreted your point of cutting the hole in the backdrop. I thought you would have to remove it to cut the hole, but the Dremel solution works just as well!

Hopefully the Saw Max solution works.  Otherwise, I will be up that certain creek without a paddle.  

George

Updated 7/17/2018:

I mocked up the bridge against the backdrop to see how it would fit (pretty close approximation of location).  Here are some photos.  Note that this is only the main span.

That's it for now.  

George

Awesome bridge George.

Dave NYC Hudson PRR K4 posted:

Awesome bridge George.

Thank you!  And there is still 6' of it you haven't seen.