Even I am a member from 4 years now, this is the first topic I put on the forum.

This is a small tutorial about the use of the Howard Zane hardshell Method.

I found this a very easy method to use and fare more important It did'nt produce dust.

The hardshell is very strong, but light in construction and very fast; You can cover "yards" of hardshell in a very short time.

I build this small diorama in Nscale for me, as a try of the method, but also for a train show here in Belgium to explain and show the Zane method.

He explain in details his method in his book about his fabulous layout,  ( http://www.zanestrains.com)

The structure of the hill is cut in a sheet of Gator foam, glued to the base whith a hot glue gun.

I have use a large piece of Gator Foam (GF) as a back for the hill.

Directly, You feel the structure is very strong.

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A lattice of cardboard strip is glued on the GF structure like usual whith a hot glue gun.

Here in Europe we can't find Red Rosin Paper, so I use a similar paper, but Mister Zane use Red Rosin Paper; it's cheap and easy to use, just cut pieces whith a scissor and hot glue them on the lattice.

When the whole structure is covered whith paper,  I brush generousely full strong white glue on it and let it dry for a full day.

Because the Clemi mine is set in Virginia, I add some plaster casting to the hardshell. You could cast them in place, just wet the surface whith some water; or cast them at the worbench, I use both methods on this diorama.

The casting are painted as usual, in place or at the workbench, Your choice, but by working at the worbench You avoid any dust and mess on the layout.

When the casting are painted, the rest of the paper shell is painted whith a green forest color latex paint to hide the color of the paper.

Piece of Woodland cluster foliage are glued to the shell to represent the forest canopy. I use a translucide latex glue used for floor carpeting which is extremely tacky and drie fast. only small area are covered whith glue at a time.

In the same time the track is glued on the base, I use ME code 55 track, spray painted, whith some ties retouched here and there whith various brown and gray color to kill the uniformity. The file of rails are also individualy painted whith Floquil tie brown.The track is ballasted as usual and when everything is fisnished, a black wash is put in the middle of the track to simulate oils and grease. I also put in place the contour of a small dirt road and some ground foliage all by Woodland Scenic.

The hole in the track is for fallen coal because the mine will really transfer mine to the hoppers.

The small diorama finished and the mine in place. However the mine is still under construction; its an heavily reworked Blair Line "Cash Mine" in Nscale.

The method is extremely easy to use, neat, fast and strong and more important whithout producing any dust.

The GF is an extremly versatile medium and I will use it whithout moderation on my expanding layout, the Maclau River RR in Nscale.

Thank You for the innovation Mister Zane.

Marc, from Belgium.