Peter's Model Railroading | The Layout | Layout Benchwork
Hazel Mine Modules Benchwork

The next phase of the layout is to build the next two modules to expand on the one completed module, which is shown here in this photo. To be able to do that, and to better envision how I am going to set up this expansion, I needed to re-arrange things in the room where my layout is housed. I had built this stand that rests on the top of the office desk I use. The first module fits on there perfectly, but if I were to expand the layout by adding a module to either side of the first module, they would make moving around in the room almost impossible. This was because the desk was in the center of the room. So, the next evolution is to put it up against one wall in the room.

By rotating the first module 90 degrees on the stand, I can fit two more modules on the stand, and have them all stick out away from the stand by exactly 12" all the way around. This photo shows two more Gatorfoam board sheets placed in the spots where the other two modules will sit. The total space coverage will be 6 feet wide and 4 feet deep. This was just a see-what-it-looks-like concept, which quickly proved to be unwieldy, as I kept bumping into the sheets as I moved around in the room.

So, after spending a lot of time thinking about how I can build a better way to support three modules, work on them, while still having good access to everything in the room, I finally settled on this design. The idea is that there are two 8-foot long I-beams that span in between two metal shelving units I have in the room that store all of my model railroading and other "stuff". The shelves' height determines the vertical position of the two I-beams, which will likely be at about the same height my one module sits right now, or around 57" from the floor (minus the height of the I-beams themselves). I-beams (shown in brown in the diagram) are good for this kind of an unsupported span, and the modules don't really weigh that much. You can see the three modules in the three different shades of green, with the middle one representing the module that I have already completed. By making the I-beams 8 feet long, I can, theoretically, add a fourth module in the future, although I won't be able to do that when using the metal shelving unit I am using now. My initial vision for this whole scene is to have four modules (after that I plan on starting a completely different scene with additional modules).

This diagram shows the planned ladder-frame design of the support structure. Each of the two 8-foot long I-beams (brown) are held apart by four 25-inch long I-beam sections (yellow). These are flush with the long I-beams so that there is full support for the whole system and the three modules that will sit on top. The beams will be made out 6" boards (nominally 5-1/2", as drawn), to avoid any sagging. The top and bottom boards, forming the "I", are there to keep the main board straight. The tallness of the I-beam will also open up the opportunity to perhaps hang small tools off of them, since this "benchwork" will sit right above my desk/workbench.

After building this support structure, the next plan after that is to build two new modules, one to go on either side of the one I have built. These represent the mine's in-feed and out-feed tracks. Each package of Gatorfoam contains ten 3' x 2' sheets. I need about 6 sheets to build one module. So, I have about 4 sheets left over from the first order. Together with a second package of Gatorfoam, I will have enough sheets to build two more modules. I plan to thoroughly design these two modules, and then at some point purchase a package of ten sheets. I will then build the two modules at the same time. This will optimize my time in the garage with the woodworking tools, because I can set them up and make all the cuts necessary for both modules. My tablesaw is the only flat surface that is long enough to support the module, so actual assembly will be done one at a time, but with the same steps executed on each and in sequence. Again, if I do it once, I can do it the second time even faster.

For my first module, I didn't know if it was going to work, and I had to develop my own instruction sheets to build it. I don't have to do that for subsequent modules, so that will save quite a bit of time. However, the second and third modules will have to deal with the issue of how to accurately mate up with the first one. So, I will have to deal with how to connect them to one another, how to keep them aligned, how to disconnect them, and during the track-laying stage, I'll have to make sure that the tracks line up with the first module. So, there will be additional challenges to overcome with this next phase of the layout.

Since I use battery-powered locomotives, I do not wire my track, so there is no need for dealing with how to electrically connect the modules. Physically, I am currently thinking about installing dowels/pegs to be glued into one of the modules, and an opposing hole in the other module. These would then handle the alignment issue. I am also thinking about gluing in two or more rare-earth magnets, which will be the "clamping" force that will hold two modules together. This will make assembly and disassembly a snap (pun intended), and there won't be any external clamps or anything visible on the layout. My experience with the first module is that it is heavy enough to not move easily on the desktop stand, so there will be no need to clamp the layout down to the I-beam support structure.

Long-term, and especially if the price of a sheet of furniture-grade plywood comes down, I would really like to build a cabinet system for my room. It would go against one of the other walls of the room (no windows), and span the entire width of the close-to-ten feet room. The center 4 feet would be devoted to my office space, the remaining left and right 3-foot sections would be space for workbenches for projects and other things. There would be storage shelves above the work surfaces, and then, at about 52" above the floor, there would be two I-beams that will hold the four modules of my layout. It is going to take me quite some time to complete the next two modules, because one of them will have a number of different structures on it. The long-term plan would allow for an additional module, for a total of four (which would require the purchase of an additional box of ten Gatorfoam sheets). It will likely be an expansion on the right-hand side where the Hazel Mine yard starts to curve toward what is the front of my layout. That fourth module may not need to be the full 4 feet deep as the first three need to be. That fourth module will have mostly track and at least one or two turnouts on it. All of the content of this page is highly subject to revision; I just wanted to capture my thoughts on the next phase of the layout, and to spend some time documenting my ideas.