lets start the process
Time to add the ore dock in Agate Bay, MN, on my Splitrock Mining Company layout. I was going to build a couple of Walthers kits, but was offered a built up, two kit dock by a friend who did not need it anymore. I would have to do some detail work on it, but having the core part done saved me a lot of hobby hours.
Dock stripped of detail parts and ready for rails
I removed the track that was attached and all the ore chutes and mechanisms. I cleaned it up and removed most of the approach structure. The kit has a single track approach, I needed two tracks. I removed my trusty Faux-dock, and thanked it for all its service.
My Faux-ore dock. Two tracks on a board with photos of ore chutes.
Approach area removed
I then created a wooden base so I could add a detailed pier section going into the bay off Lake Superior. I am going to simulate steel pilings all around the base using corrugated styrene cut to size. Once I found the location that the dock would be placed at, I marked the base of the harbor. I then added solid wood base to my bench work. Track came next, as I needed the dock to operate so I could get back to hosting sessions this spring.
Rail added and glued down. Fast Track Point Forms make great weights.
I had to move the approach and find a way to support it until I built the dock bracing for the approach. I drilled a ¼ inch hole in the wooden approach and inserted a T-nut. I then spun a threaded rod down to the base. I drilled another ¼ inch hole in a piece of the base wood to give the rod a place to fit and stabilize. I then twisted the rod until the approach was level with the dock deck and Agate Bay yard.
Approach with threaded rod into T-nut for stabilization and leveling.
Rod will be cut off at track level, and bottom of it hidden by scenery.
This will all be covered with scenery in the future. Minnesota Hwy 61 will be going under the dock on its way between Duluth and Grand Marais and the Canadian Border. Time to install some rail.
Bumping posts will be added at end of dock tracks, prevent adding too much iron to Lake Superior
I used Micro engineering code 83 rail, and joined two, three-foot pieces to get the length for each track. I cut a rail joiner lengthwise and soldered the rails together. I cut them lengthwise so the rail would fit flush against the guides that are molded into the top deck, without the joiner pushing against the outside of the guide. I then painted the rail with a Krylon Camo spray can. I also painted the top deck of the dock a rusty, brown color, and touched up the concrete color on the cement shoes at the base of every vertical beam. Lots of detail and weathering will be added later, I just wanted to get the basic parts painted. I used liquid nails on the bottom of the rails and held them down with my Fast Tracks point forms and Micro engineering track gauges to keep everything parallel. Now onto building the custom turnout for the approach.
Old ore dock turnout. Thanks for the memories!
New curved turnout laid out with PC ties from Fast Tracks
PC ties glued down and curved frog positioned
I needed a new turnout to service tracks one and two on the dock. I removed the old turnout I had built, it worked great for the faux dock. I used Charlie Comstock method of placing flex track down to see where diverging routes will go. This helped me locate the frog and points for this custom turnout. I drew the rail lines in pencil and started to glue down Fast Track copper plated PC ties.
Outer rails added, track gauged with ME gauges and NMRA gauge for the frog and points
Once I had the ties in place and secured, it was time to add the rails. I learned from the hand laying masters that you should build a turnout from the inside out. I started with the frog and used the Fast Tracks Frog helper and rail roller to get it curved. I then added the outside stock rails after notching where the points go with a Fast-Track Stockaid. I soldered these rails in place, using my NMRA rail gauge to check at the frog and points, the two very critical parts. I then made point rails with my FT tools, and curved them to the correct radius. I used my NMRA gauge once again to make sure the gaps for flange ways were the correct distance from each other.
First point rail installed.
Both point rails installed
Next came connecting the turnout to the dock rails. I used more FT PC ties, and will fill in the gaps with stained wood ones at a later date. I also made a slot for my moveable Kadee Delayed magnet. I like hands free operation. I have a sliding magnet hidden under the track so I can place ore cars exactly over the assigned pocket. I do not want operators to be reaching in and harming any dock details that will be added later by using uncoupling picks. I built this out of scrap 0.040 styrene. I put the metal plate on the bottom of the styrene, and the big magnet on the top. I then attached them with CA. I also built in spacers so the magnet will be directly under the rails when I slide it back and forth with no guesswork from operators. I will cover the magnet with a piece of 0.020 styrene so it matches the deck and is hidden.
New approach being built. magnet will slide and be hidden.
PC ties glued to styrene, magnet covered by 0.020 sheet
I connected the rails and soldered the rail joiners. It was now time to cut the electrical gaps. I much prefer to do this portion BEFORE I install a turnout on any layout, but since this was build-in-place, I had to improvise. My trusty Dremel Moto-flex and a cut off disc helped cut the PC ties across the top. Proper eyewear is essential, and I always use it. I then used my Dedeco Thins cutoff wheels to cut the gaps in the rail to isolate the frog. I went back with a dull X-acto knife and a file and made sure all the PC ties were properly gapped from rail to rail. After testing with power applied, I still had to find a couple of pesky spots that caused shorts.
Cutting gaps in the PC ties
Cutting rail to isolate frogs
Now that the rails were installed and gauged and gapped, it was time to add the throw bar and Bullfrog. I used another PC tie for the throw rod, and moved my bullfrog and wooden dowel throw rod over to the new location. A ¼ inch hole was drilled to fit the dowel rod. I use a wooden ball glued at the end of the dowel, I get them from Michaels. A new wire from the Bullfrog to the turnout was added, and after testing, cut to length. Use a good wire cutter on these, NOT your rail nippers. These are great devices for hands free operation, and I have modified a few of them for custom purposes, but that’s another blog post for later. I also hooked the frog up to a Tam Valley frog Juicer, so everything stays powered on the long dock shoves.
Hole for throw rod drilled in bench work, and in PC tie
Throw rod soldered to point rails
Moving bullfrog and throw rod. New wire to turnout needed.
Holding throw rod in place while Bullfrog is attached to underside of bench work
Wire cutter to nip off Bullfrog throw wire
New hole in fascia for throw rod
Ore car rolling over completed turnout.
Now it was time to test it out. A little cleaning of the rail to remove paint and solder and flux, and we could try it. 99% rubbing alcohol and a wire brush clean up the flux and solder quite well. The first couple of tries showed some electrical issues. I forgot to solder a couple of rail joiners, and I forgot to add power to the inside rails off the turnouts, so no power was running to these rails. These were gapped after isolating the frog. A couple of drop feed wires to a handy terminal strips and I was back in business. I had to do a little more filing on the frog points and finish soldering the wing rails. It’s amazing the little things you forget when you get excited to see trains run.
Wiring up the Tam Valley Frog Juicer.
So after a few more tweaks the test was a success. I can now get back to operations and plan the details and scenery around the dock. I hope my ore boat arrives soon so I can add my “Signature Scene” to Trevor Marshall’s wonderful thread. I included a little YouTube video of how the dock operates. It was a just a test run for fun and to show off my work.
Thank you for reading and following along. Now enjoy the video and comment away.
Thomas Gasior
