TOMA Phase Two: New Module & Next Steps

Underside of the new module

The new module's benchwork is complete. Since my last post I completed the process of glueing and screwing the plywood top to the framework. After the glue dried, I drilled some holes through the framework to later run wiring. I also cut and glued on some wood spacers to support the fascia once it is time for that step. After those dried I went ahead and primed the underside with a latex primer. 

Now that the benchwork construction of this new module is complete, I revisited the penciled in track plan on its plywood top and started test fitting the track and roadbed. When I ordered track, turnouts, and roadbed a few months ago, cork roadbed was not available, so I went ahead and purchased some of the new Walthers closed foam roadbed. I also purchased Peco flex track, which I hadn't used before. Since I am using Peco turnouts, it makes sense to use their Code 83 flex track as well. 

By temporarily clamping the new module in place, I not only identified a slight angled gap between the modules, but I was also able to accurately position the end of the roadbed. In working with the Walthers roadbed, I found it to be less forgiving, perhaps because it is full width, with curving easily. I cut a small straight piece to glue in place here at the junction with the existing benchwork, ensuring that the subtle s-curve going through the fill would be from one length of the roadbed. Walthers says it can be glued, but does not specify what type of glue. I tried Weldbond. 

After the Weldbond dries, I will unclamp and move the new module back to the sawhorses to more easily work on finishing installation of roadbed along with the track and electrical work. I will need to review prepping the Peco turnouts before pre assembling the turnout section. Along with installing the trackwork, I will want to at least start some of the electrical work such as the track feeders and DCC bus with the underside easily accessible. Unlike the track and roadbed components which I ordered ahead of time, I'd better check my supply of switch machines and wire. I also have some infrastructure work to complete: hardboard for the backdrop and a new LED fixture for lighting will need to be purchased and installed as well as prepping and painting the floor before permanently bolting the module into place.  

TOMA Phase Two Underway

Revised Phase Two Sketch

I left off my last post with a desire to revise my plan for Phase Two and start with the new benchwork. As seen above, I shortened the plan for the new module and came up with this working plan. 

After sketching the plan, my next step involved unburying the sheet of half inch plywood from the back of a pile of lumber in the garage and purchasing a new blade for my Skilsaw. Still out in the garage, I cut a two foot by six foot section to bring into the basement to work from in order to fashion the top of the benchwork for the now six foot long cut and fill module. My plan was not to just create a flat rectangular benchtop, but to incorporate a curved front as well as some lower sections for the "fill" to rise up from. Later I will create the hill with the cut on top of the plywood base.

Using measurements of where the track on the modules to either side will be, my layout plan sketch, and some track I drew out the track plan on the plywood. If you click on the photo to enlarge it, you can see where I drew in the curved front of this new module. I started sketching in the track plan in pencil at this point as well, but I went over the curved front with a marker to make it easy to see. That will be the first cut with my saber saw. 

After cutting out the curved front of the plywood panel, I continued with drawing the track plan on the plywood. I first sketched in some initial ideas for the lowered section or ravine that will be cut out. I also did some basic calculations to get an idea of how low these dropped sections need to go. I have a trestle that I built from a Campbell kit years ago that I plan to use on the drill track. I also have a concrete culvert kit for the fill section. I wanted to make sure I had room for these. Then I cut out those sections that will be dropped below the rest of the plywood top. 

After cutting the plywood to its final shape, I started designing and construction of the grid framework. In this photo, it is completed and resting on sawhorses, ready for the installation of the top. To actually build the grid, I had the plywood on the sawhorses and laid out the "one by" pine panels on top of it. I used basic glue and screw techniques to put the grid together.  Having two drill motors made fast work of drilling and then screwing the parts together. 

In this photo from earlier today, the top and recessed areas are positioned in place, as is the trestle. After I took this photo I went ahead and glued and screwed the plywood top in place. One trick that I tried before final assembly was to reposition the plywood under the grid on the sawhorses in order to pencil in exactly where the grid frame pieces would be before reconfiguring the panel back on top. I also avoided positioning screws under future track locations as well as countersinking the screw heads, so they would be hidden under future scenery. 

I plan to continue working on this new section as a module as I find that it is much easier to complete some of the next steps by tipping it upside down or on edge rather than crawling under the installed benchwork. I need to complete some more prep work before installing this section as well; floor painting and extending the backdrop come to mind.

Basement to Trainroom Continued

Earlier this week I finished painting the foundation walls, completing one step of the transition to trainroom. While nowhere near as wet as last spring when the sump pump failed, the floor has a couple of areas where the existing green paint is missing and moisture is seeping in. A next step, painting the floor, will have to either wait or be done in sections avoiding moisture. Generally the "French Drain Canal" has been channeling the water to the drain in the far corner of the basement successfully, and the existing green paint seals the moisture away.

When my wife and I moved the Ferndale Junction module into place, she pointed out that, even with the fold down section, she felt it was too close to the well pressure tank and inlet plumbing. Her point is that we should allow room for someone to work if (or when) we need work done. So, we moved the module back a bit, and I have been sketching out a plan for a six foot rather than seven foot module for the new section between Nooksack and Ferndale Junction. I really don't want to set myself up for a serious "I told you so" situation. 

Next steps appear to be some floor cleaning and painting as well as finalize the plan and get started on the benchwork for the new cut and fill module/section.