Category Archives: Progress

March 2015

We’ve carried on working hard since last November and have pretty much completed all the baseboard work now. It’s not shown in any detail, but we cut the old staging yard off the back of the main baseboards, leaving just two tracks, which are for testing and programming – one will be DC. A 1ft strip was also removed from the left hand (tunnel) end to give a total modelled board length of 20ft to match the staging yard.

The cutting was done with a rotary saw and finished with a hand saw. The edges were then faced with fresh plywood, suitable braced, glued and screwed. To finish this part of the reconstruction the remnant rear main boards (now about 4ft x 1ft6in) were permanently attached to the front main boards (the original 4ft x 2ft6in) using PVA glue and screws through the bracing points. This means that we have four boards 4ft square and two narrow end boards – one 4ft x 1ft6in and one 4ft x 2ft6in – slightly awkward but – hey!

The photos show the new centre well that this configuration gives us – big enough for even the larger of us (I won’t say who that is!) to move comfortably along, although we can’t easily pass except in the ends.

New legs were constructed for the end curves. Also shown above and below is a (re-) railing track which is switched to avoid shorts. Connecting the boards up in the final configuration meant that we could finally lay the connecting track at both ends – shown below.

A brief diversion here into the techniques used to ensure that where the track crosses a baseboard join, the stock doesn’t derail. Portable baseboards are the norm in the UK and so this is a major problem. Critical to ensuring that track stays aligned is ensuring that baseboards align in the same position each time they are reattached. The best way to do this is to use board alignment dowels. The best ones have a point in the back of one side that lets you align the two sides for drilling. The second and third photos show these in our board (after the curvy edge system had failed to align the boards well enough!).

The wiring on the front had been installed many years ago, and so the switch control wiring was disconnected and then rewired to MERG DCC boards to give the same switch control system as in the staging yard. Note that the DCC switch control boards are always attached to a vertical surface to make maintenance easier. One switch on the front (on a curve) was replaces with a commercial Peco switch – which has proved better, but not perfect.

Everything working on the boards, we then moved on to the lighting and the gantry. After seeing a layout at the Mickleover (Derby) club using an aluminium folding ladder to support the lighting, we managed to purchase a 20ft ladder that would work for us. Although it was not completely level when supported at only the ends, it was rigid and so the slight central dip could be accommodated when mounting the fascia boards.

Lights are DC (12v) halogen, wide angle floods of 20, 35 and 50 watts. We attached these to the bottom of strips of plywood at 45 degree angles with basic lampholder bases. Along the top of each board were the transformers and the wiring. The plywood simply rests on top of the ladders and the fascia hangs off the front. A simple H frame at each end supports the ladder.

All this work completed, we decided to put our stock out on the staging yard and were quite shocked by how much we had – especially as most of our locos can’t pull such long trains. Still quite a lot of weathering, re-wheeling and Kadee-ing to be done though!

Finally a shot showing a consist of new (as yet undetailed) Athearn RS3s and then one with a N&W articulated interloper with a long empty coal train (note that the buildings have been removed for safe keeping). We are now moving on to add more hillside and roadway at the RH end, and then will work along adding detail to the scenery.

November 2014

Despite my hopes that the updates to the site would become more regular after Gordon’s retirement in April and my continued life of leisure, what has actually happened is that we modelled at a high rate instead. As Doug is working a four day week, we modelled on Friday mornings as well and this made a big difference.

We had a good summer and used this to carry out repairs on our clubhouse – including demolishing a 120ft portacabin which also kept us pretty busy!

Here we are starting to lay track in the staging yard – if all else fails, hit it with a hammer! Even my daughter came in to lend a hand on a visit back from her midwifery course. The track laying progressed well. By August it had pretty much all been laid.

In the meanwhile, Steve was working on customising some SW7s and SW9s for the CNJ. Athearn and Proto-2000 stock was used as the starting point. Both jigs and hand bending were used to prepare the CNJ-style handrails – some were soldered, but most were superglued.

Handrails were added to different styles depending on the prototype, as were minor variation in the vent stacks. Once handrails (and some grab irons) were complete, the bodies were airbrushed with my own mixture of gloss green. RBH water slide decals were then applied carefully and the models were then sprayed with matt cote. Finally all were weathered with a mixture of techniques. Three were chipped and one set up as a dummy as not all the motors were usable.

Meanwhile, back at the club, the hard work of wiring up the track and switches was proceeding – led by Doug, but with all three of us taking a share. Later, Doug withdrew from this exciting activity due to pressures of work and other interests, but we continued to fit and wire switch motors (Peco) with the help of Bill, and MERG DCC switch controller boards. These latter were mostly built by our club specialist (Derek) and wired in by Steve. Derek then configured them for us.

We set up computer control with the Big Bear software package – which works well. The track panel component (left) can be downloaded for free.
..and all the time the trains kept running round! We are now cutting and reconfiguring the old baseboards, removing the old staging yard, and hope to have finished this stage before Christmas.

April 2014

Although the five 4ft by 33 inch staging yard boards were already constructed, we still had to make the curved end boards. The photos show their construction. We again used a ply base and softwood bracing, but the sides were from 4mm MDF board which bend nicely. All held together with screws and white glue (PVA).

Doug came up with a support system reminiscent of that used on the scenic board, but this time using a softwood T-section. This fits into slots on the top of the trestles. and is very strong. The last two shots show the end boards and the first staging yard boards erected a couple of weeks ago (that’s me being smiley!). Finally a few shots of the stock running while we extend – I’ve been weathering the F3 units and cabooses with Pan Pastels after the article in Model Railroader. Generally we’ve been very impressed.

Paul and Dave are still modelling nearby us in the clubhouse on their EM (4mm scale, 18mm gauge) layout of a local station and we often go for a drink with them after the modelling sessions.

Hopefully the update to the site will become more regular now. Gordon is retiring this Friday (Easter Friday) and I was made redundant last October so am semi-retired at 58. Doug is working a 4-day week so often has Fridays free. All-in-all this should mean more modelling time as we start on track laying and wiring.

2nd half 2013

We left the layout with construction just starting up again in May. Here are Doug and Gordon working on the new staging yard baseboards – plywood top and softwood bracing. I’m helping by taking photographs. We used ‘EM-gauge society’ baseboard locators – metal pin and holes that screw to the ends of baseboards; These are visible in the third picture where we are weighing down the cork with anything to hand. The fourth picture shows an unusually summery set of modellers and below that are some shots of the layout in July.

Also in July, we completed purchase of the clubhouse from our local council and that meant that the plans to move into the main hall, with more room for our extension, became possible.

As some of you will know, we were very sad to lose Chris Bennett at the end of August – he had prostate cancer and had been in hospital and then a nursing home since the spring. His modelling prowess is evident in so many of the structures on our model of Mauch Chunk, as well as in the overall construction. He is sadly missed.

Over the Autumn (= the Fall) we finished the baseboards while one of the other groups modified the new annex building that we had acquired on the site. This would mean they could move there out of the main hall making room for us. After the end-October exhibition, which their layout attended, they duly moved into the annex. We cleared the space left and in January moved Mauch Chunk through into the main hall. We were delighted that even with inexperienced modellers we dismantled it in a couple of hours and then re-erected it (see photos above) in another couple. At the end of this we had stock running! A testament to Chris and Paul’s construction and wiring.

2013 weathering

Much of the activity so far in 2013 has been in sorting out rolling stock. Removable coal loads have been prepared for all the hoppers using real coal, sieved down into different size ranges and glued to foam shapers. Photos show the basic process and a variety of the results.

All the hoppers have also been weathered inside and out for consistency using acrylics, weathering powders, Tamiya weathering pads (& make-up applicators – see first photo below), Tensocrom liquids to simulate oil and water spilss, and astonishing Rust effect liquid. ..also an airbrush. The techniques are all described in the UK ‘Model Rail’ DVD by George Dent – ‘The Weathering Expert’ – quite outstanding and worth purchasing even from across the Atlantic, if you can be sure it will work in a US DVD player. These are the main products and implements used .

I have also weathered most of the boxcars (some shown below), some tank cars and some switchers. Weathering is hard to photograph, but hopefully some of the photos will give some idea.

Chris and I have also each started to modify a BLI Mikado to an M3a CNJ Mikado. It is still fairly early days but the photos show the steps in producing the classic Wooton firebox. Many more photos to come but it won’t be quick!

End of 2012

Things continued slow throughout 2012 as we negotiated our way through finding funding to purchase our clubhouse.

I (Steve) am Chairman of the Merseyside Model Railway Society, so I have been very tied up in this. However, the very good news on the modelling front is that we now have several new modellers: as well as Gordon who joined us last year, we now also have a new club member, Doug (a South African) and John who has moved back to HO American after several years in the wilderness. Along with Chris, who is sharing his expertise with the EM group mentioned in the last update, this makes 4 and a half modellers. We are raring to go with the next stage!!

Here are a few photos which show quite an atmospheric Mauch Chunk. They also show the completed 2.5D backscene buildings, and repainted hillsides, although there is still work to be done there. Colours are deliberately muted in some photos.

May 2012 – some more..

The great task of installing a continuous backscene finally started: A support of 4mm MDF was found to be flexible enough to curve round the ends and the two painted sheets that had previously been used in the middle were used (which is why the painted hills are in the wrong place at this stage). Suitable wooden supports and frame were built to provide more rigidity than hitherto. A new sheet was installed in the middle.

The intention is to use a continuous sheet of matt laminated paper or plastic, which we will paint before lamination. This will stand in between the backscene and the model (it has enough rigidity) and give the portable continuity, without any gaps, that we are seeking. It may even work!

To sit in front of the backscene, slightly 3D buildings – the courthouse and navigation building – are under construction. They are made of perspex and plywood which provides non-warping rigidity and ease of working. Roofs will be made of thick plasticard. These will be coated with matt laminated photos built up from mosaics as used in a flat form before.

Some more grass has been added to the between-tracks area following a close examination of some of the photos “from above” taken in this period. It looks as though a couple of buildings were removed, leaving unleached coal waste from underneath them on which no grass would grow. That’s my interpretation, anyway!

There’s still quite a lot of finishing off to do. Personally I have been levelling the kadees on all my stock and still need a few metal wheelsets. More DCC chips are beeing installed and a few items need remotoring. Biggest is scratchbuilding a CNJ signal bridge using brass etching (if you might be interested in getting one of these, please let me know and I will try and design the etch to handle 2, 3 or 4 track bridges).

Last but not least, an airbrush set-up is being assembled with the intention of serious (but subtle) weathering for everything. Years of fun to come!

So still a few bits to do before we can exhibit it again. A few other club members with American modelling interest are beginning to show their heads in our room, so we hope that we may have more help once Paul, Chris and Dave focus on their new creation.

May 2012 – little bits

Things slowed down somewhat after the exhibition. This was for a number of reasons: Firstly some of the group members wanted to move on and build another small layout. Second, the remainder want to make modifications to the staging yard using longer switches so that the stock will pass through it more reliably. However, how this is done (Plan A or Plan B) depends on whether we have more space for the layout and this depends on whether we are able to buy our clubhouse – which has been under negotiation for over a year, although the decision is close.

So, I (Steve) have done much of the modelling this last six months, ably assisted by Gordon, while Chris, Paul and Dave try to decide whether they want to build Patagonian narrow gauge or an LNER branch line. Paul continues to provide able support for the electrics! It’s been lots of little bits, plus trying to get the backscene sorted.

Firstly I have added a few detailed scenes with characters, carefully inserting the ends of pins into legs and then into the sidewalk! (yes, some did lose legs). Many more are still waiting mutilation and gender realignment to fit 1940/50s Mauch Chunk. Awnings were also added to some of the stores and trash was placed in the dead spaces where old buildings have been demolished.

Oval switchstand targets were etched in some quantity and then attached to a variety of commercial switchstands, together with or instead of lanterns, and then painted with enamels to give the desired effect. To date only a few of these have been installed on the layout as they are rather delicate and have a tendency to get flattened.

June-October 2011

These photos were taken from June through to October and provide a record of the work we did on the layout in that time period.

Dave spent a lot of time building the variety of telegraph poles and electric utility poles found in Mauch Chunk (according to our photos). These show them as built and weathered and then in situ – showing how they really add to the mood of the scenes.

Steve then did another brass etch including some fencing to go round the back of the park and some windows for the track sheds, which were then built by Chris from laser cut strip wood.

The Mikado M3 was painted for us (still to be weathered) and a Babyface A/B unit purchased from eBay, as the price has dropped since the ARHS body shells became available. Also another K1 unpainted from David in the UK.

Chris designed and built a new lighting gantry that can be transported in two parts but bolts together to give a single 15ft span so that the view of the model is not interrupted. Works brilliantly.

Last, but by now means least, Paul has modified and built DCC kit that gives us separate power supplies to the two directions of travel, so that shorts will only stop one direction at a time. The power has also been boosted so that locos with older motors can be run. As is so often the case, this was not photographed as it is under the layout – I’ll try and do better next time!

So by mid-October, everything was ready for the Warrington exhibition. See the photos on the Exhibition page.

May 2011

A lot of detailing work was done in early 2011: grass along the lineside using static grass, lineside fencing and some of the more ‘interesting’ telegraph poles that overhang the river! Additional foliage was also added in various places.

An attempt was made to provide some waves on the river to stop it being mistaken for a lake or a mill poind – sadly this failed. Whether this was operator incompetence or poor material we don’t know. The river was taken back to the base and reworked up to its previous shininess.