Every now and then I like to go back and pick an older building to replace or rehab.
The 'chair factory' was chosen for this rehab project because of its proment place on the layout.
Current project Rehab work Started on 10-15-12
The Wayside Furniture Factory was built about 15 years ago to fill in the oval on my trolley line. My intentions were to
complete the interior at some point. Well the point has finally arrived and work has commenced.
Background- In 1954 while in high school in New Haven I was able to get a job working after school and Saturdays
at the C Cowles factory. Still exists. They were a subcontractor to the auto industry making the ash trays, chrome trim,
window cranks assemblies, etc. The place was my first experience to what a sweat shop of the early 1900s was
probably like. The machinery was modern for the time but the ceiling was original with all the belt drives that once
powered them. In the course of my senior year and that summer I packed boxes, worked in the plating department,
operated a punch press and worked in the window assembly area. I hasten to mention that in the following two summers
I was able to work for Pratt and Whitney grinding the blades for jet engines and in internal trucking. The two factories
were a night and day comparison.
For my interior I wanted to recreate the appearance of Cowles as best my memory and imagination can recall.
This 3 story building would have the initial wood work performed on the first floor. Finished wood working on the
second floor and final finishing and painting on the 3rd floor.
Photo- 1 
The building was constructed in styrene sheets faced with Hollgate & Reynolds brick. Windows
were scratch built using styrene strips. Similar architecture to Cowles except I gave my building a large dust collector while
at Cowles we were allowed to open the window a bit. That was until Mr. Costello who owned the company came around
and closed the window and unscrewed the light bulb we were working under and said "the window gives enough"
I have recently upgraded the exterior by adding a pair of cast iron doors to the front. 
First Floor
Process- Lumber in 8' x 12" widths was brought into the building and stacked based on the orders. First step was for
a layout person to check each board and mark the best yield. He would stack this lumber for the Chop saw operator
who would cut the board to varying lengths and put the cutoffs into carts for movement to the next operation. All cut lumber
was then sent to a planners who would surface the thickness as required. Small sections for chair seats and backs would
be edged on both sides for possible glue ups. The longer lengths for legs and arms would be edged and sent to a rip saw
operator. All of the ruff cut pieces would then be sent up to the second floor.
Photo- 2 This photo illustrates the steps described above. The large white square in
the lower right is the top of the freight elevator.
Second Floor as of 12/24/12
Office portion-
Photo 4-
Note: All of the office furniture
shown (desks, chairs, file cabinets', safe, and book case are available as castings on the Internal page of my
web site. www.westportmodelworks.com The woman shown in a blue dress is responsible for invoices, receivables,
billing etc while the woman in the red dress handles production scheduling, inventory and payroll.
Factory portion-
Close up of workers cutting seat, and chair parts from wood blanks. Also shows workers creating
mortise and tenant on chair parts and glue up seat and seat backs.
Photo 5-6- Close up of workers cutting seat, and chair parts from wood blanks. Also
shows workers creating mortise and tenant on chair parts and glue up seat and seat backs. Another detail photos of
workers turning chair legs etc.
Photos were taken prior to installing machine drive belts.
3rd Floor as of 1/20/13
Final prep and chair assembly and finish.
Top views of 3rd floor. On
this floor chair parts are sanded, assembled, upholstered and chair
are placed in a finished good rack before being taken down to the warehouse and shipping department.
Work remains on adding the sawdust collection venting that feeds the cyclone dust collector on the roof,
Roof and exterior upgrades Work to begin shortly
You can view the progress of this project on my web site www.westportmodelworks.com or email me at wsptmdlwks@gmail.com . I would appreciate any suggestion for improving the detailing of the interior or exterior.
Les Lewis
