Module construction - my new module and many build photos
I recently "completed" (when is a railroad ever really completed?) a new 24x72" module as part of the California Central Coast On30 Modular group in the SF Bay Area in California. The module follows the CCC standards with a defined 24x4" connector plate and the through track offset 6" from one side.
The module construction is box beam, with the sides of 3/16" lauan plywood and 3/4" white wood spacers. One side of the lauan is the fascia. The ends are 3/4" plywood and the overall depth is 9 inches. The notch is for the canyon. This is a view of the basic frame before the fascia lauan was installed. Everything is glued and teh nailed using an air nailer. All of the major components are screwed as well. The overall frame weight is about 5 pounds without the legs.
This is a view form the side:
The cross bars serve two purposes, they keep the module steady and they attach the legs. The legs go into pockets with a finger that is tapered. I can set up the module by myself by lifting one end up onto the leg and then the other. The cross bars can be set flat to the ground to keep the legs vertical dusting set-up. This is a picture of the leg pockets with the leg inserted.
This is a picture with the base lauan installed and the pockets for the switches. I did not want the Tortoise switch machines to go through the foam and I wanted the rails at the end to be solid. Part of the reason is I am using hand laid switches (based on the Fast Tracks templates) and, as they are code 100 per the club specs, they are relatively hard to throw. Also, a number of the modules in our club have issues with the rail being pulled up at the ends, so I wanted a solid mounting. I made the switches using PC ties so they are solid. I would recommend using either PC ties or American Tie and Timber Gapmasters (made by one of our members!) for at least one inch at each layout end.
Note that I pre cut the holes in the fascia for the switch controls and the plugs for the MRC DCC cab control. I painted the fascia green before installing it and then painted the white that was taped for the switch paths and the LEDs.
This is a picture of a switch machine installed on the 3/8" plywood base (sorry it is on the side, the editor does not let you rotate):
This is another of how it ties into the foam and the 1 inch set-back specified in the module standards. As you can see, the switches are glued to the plywood as well as mailed with larger spikes. The white is 0.040" styrene that is used so the height of the PC tie switches matches the Micro Engineering flextrack used on the rest of the layout. They were lgued using ACC to the ties and then with white gule to the plywood. Overall it is really strong.
You cna see how the switches line up with teh boxes. The close end box has two switch motors in it, the second switch extends onto the foam. actually, all three switches on this end of the module were built on the workbench. This is an underside picture with the wiring complete. I used latching relays so the switch machines are push-buttons form both sides and added sound and lighting to the buildings. The relay circuits are under the small plywood squares for protection. You can see how the Tortoise switch machines fit into the "boxes". You can also see how the inner lauan was cut where the swithes and LEDs were installed,
Here is a shot of the completed module. I put the covers over the switches to discourage small hands at shows, though it is only partially successful.
Note the red/green LEDs showing the switch routing. They are 5mm LEDs with a brass sleeve installed int he plywood. They really look nice. I made the center switch as a single control, set toe straight or crossover to the sidings. Here is an end shot
Here are links to Google Photo Albums:
Construction Photos: https://goo.gl/photos/C9Bjf3Z9iqmP1Ddo8
"Completed" Photos: https://goo.gl/photos/1iVtRn8eSK3ZALcf6
Here is a link to the California Central Coast On30 Modular Club home page: http://www.ccc-on30.org/ccc_on30.htm Stop by one of our events and check out the modules.