When I started to build my Office Park Zone layout, I decided to replace my old Digitrax Zephyr with an NCE PowerCab. The Zephyr doesn't support functions above F9, and the PowerCab has nicer ergonomics for a small layout. While the PowerCab can handle DCC programming without a booster, it doesn't have a separate programming output, so the entire layout becomes a programming track.
The Zephyr still worked fine and I already had all the pieces needed for programming using JMRI - a PowerPax booster and PR3 USB interface. I also operate on a club modular layout and often need to bring my system to shows. By repurposing the Zephyr as a dedicated DCC programming system, I wouldn't need to worry about making the PowerCab and accessories detachable from the layout.
Here is the basic layout of the bench. All of the materials came from scrap lumber and other bits available. Since I also run at shows, I have standardized on paper boxes for transporting equipment and tools. This dictates the maximum dimensions for the bench of 17 inches wide and 11 inches deep.
I started with a piece of 1x10 and positioned the components to verify everything would fit. I ended up making it 15 inches wide to give some finger space on the sides, and space for any latches and cords protruding out.
All of the wood, except for the front piece, were cut from the same piece of 1x10. The top piece containing the programming track is secured with trunk latches on each side. It can be removed to reveal the power strip and various AC adapters. The Zephyr adapter is the largest one and is 4 inches tall when used with this particular power strip. I cut the back, sides, and top to completely enclose the adapters and wiring.
The front fascia is a piece of 1/8" luan. It is sized to hide all of the wiring, and also fit snuggly against the Zephyr adapter so as to prevent it from getting unplugged if jostled. The fascia is glued to the top piece. The sides, back, and bottom are all screwed together.
The Zephyr can also connect to an existing set of club modules, so I needed to retain the existing connectors. The main DCC output uses 2-pin molex connectors, and the programming leads use .100" header strips and sockets. Be sure to key the sockets and headers so you can't connect the PowerPax backwards and fry it!
Since the Zephyr has separate programming and Mainline outputs (a really convenient feature!), I put a DPDT center-off switch on the fascia so I can quickly switch between programming and mainline for testing programming changes.
The power strip is secured on the right end by a piece of scrap wood and a small angle bracket. Cut a notch for the cord by first drilling a hole in the side piece at the proper location to match where the cord exits the power strip. Then use a jigsaw to create a slot that extends from the hole down to the bottom of the side piece. A small piece of scrap wood tucked under the cord on the left side keeps the power bar from sliding side-to-side.
Alas, given the different size and orientation of each adapter, it seems a 6-outlet strip is needed just to provide enough space for the 3 adapters. This particular strip does provide enough space to permit one free outlet, along with a couple of USB charging ports for directly powering USB devices.
Use pieces of velcro to secure the Zephyr, PowerPax, and PR3 to the bench. This allows parts to be easily removed if needed. I put the "hooks" on the bench and the "loops" on the parts.
Here we see a test-fit in a standard paper box. By making the dimensions smaller (9 1/2" x 15"), there's room at the back for the power strip cord, and room on each side for the added trunk latches.
I am quite pleased with the results. The bench is compact and easy to handle. I can program locomotives without interrupting operations on the layout. Perhaps more importantly, I can easily bring the bench to the family room and do some programming work while spending time with the rest of the family!
Craig
