Z Gauge Layout

Discussion in 'Members Personal Layouts' started by Z_Downunder, Oct 27, 2017.

  1. Z_Downunder

    Z_Downunder Full Member

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    OK, here we go ...

    This continues from the posts covering our home layout at http://platform1mrc.com/p1mrc/index.php?threads/z-gauge-downunder.1848/

    Moving back to early 2011, with retirement approaching and the home layout no longer an exhibition proposition, I started planning a small exhibition layout based again on a fictitious location in Germany using just analog locos as I wanted to have steam as well as diesel motive power. Replacement DCC boards are available from European suppliers for many Z diesel and electric locos, but no one seems to have come up with a workable system for the Z steam locos.

    One early design thought bubble based on track held at the time, and incorporating a connection for the removable home layout fiddle yard at top right…

    [​IMG]

    I also began building up track and rolling stock, building kits. vehicles, etc. A few checks on skips at building sites along our street yielded a stock of various sized styrene foam sheets/blocks (we’re in a redevelopment zone with 50’s/60’s era bungalow housing being knocked down & new builds going in - also a known cause of the phone outages).

    Märklin have track switches for Z which are activated by any loco, and are direction dependant i.e. can have a different function for each direction of travel. The intent was to use track switches to alternate between two trains on each of the main lines, and to use Viessmann electronics to control slowing and stopping in the station. The branch loop and ‘mountain’ point to point line would be manually controlled, although I have the electronics to automate that track later. That, with family assistance, would allow me to be available for talk time.

    Construction finally commenced on two 60 x 80 cm (2’ x 2’8”) laminated MDF boards in late 2013, using about the 10th or 11th version of the plan, which now envisaged a future central extension with a top track reaching the 80mm level. The blue arrowed lines are a stream alignment, and the black lines approximate road centre-lines.

    [​IMG]

    Märklin also make an expandable track section in Z : 100mm to 120mm, which turns out to be the obvious solution to inter-board joints at this scale. Thus the fixed tracks have been designed with a start point 55mm from the board edge, bar a couple of exceptions (branch [purple] track at top right for the keen eyed readers).

    Peter
     
    Last edited: Feb 19, 2018
  2. Kimbo

    Kimbo Staff Member Moderator

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    Great start Peter. I Always admire people that can use the computer to map out their plans, I’ve tried several time, but always end up with graph paper, a compass, scale rule and lots of scrap paper with copious amounts of drawings and calculations, all part of the fun of starting a new project for me.
    Look forward to your informative regular up dates :thumbs:
    Kim
     
  3. Z_Downunder

    Z_Downunder Full Member

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    Thanks Kim - so on with the story ...

    Progress on the layout itself was slow as multiple trips to see the grandkids in Broome & Melbourne, plus a trip back to UK in the northern spring of 2014 took priority.

    However a considerable stock of mostly Volmer and some Kibri house kits for the proposed town area, on the yet to be acquired central extension, was steadily being accumulated via eBay, and made up …
    [​IMG]
    As to scale, the smallest kits, the standard size Vollmer kits are all 50 mm (2") long; put it another way the storage box is 24cm (9½") square.

    Once work started in earnest on the exhibition layout, much like the home layout the first thing was to apply a sheet of styrene foam to each board, then ‘excavate’ the stream on the left hand board. The culverted section of the stream under the rail tracks was constructed in two sections, using plastic straws which approximate to a 1m ∅ pipe. These were glued in place with a gap at the turn point/bend, and then slightly over ’back filled’ with Interior Spakfiller aka Plaster of Paris. Once that was dry and rubbed back down to the styrene foam sheet level, a set of manhole covers was created to cover the hole at the bend.

    This is a current close-up pic …
    [​IMG]

    With the track design finalised on both boards, and having had some success with the IBL 2mm cork underlay on the home layout, I found a craft supplier in Victoria via eBay who stocked 3mm and 1.5 mm A4 cork sheets. I bought one of each and experimented - the 3mm was too thick, especially at the tunnel portals, so I went with the 1.5 mm and sent off a direct order for enough sheets to complete the current design.

    As the idea to use cork underlay came as an afterthought on the home layout, there I had drafted the track centre lines for layout control. For the exhibition layout I laid out the edge lines for the cork underlay for the three tracks and sidings on the base level. (In hind sight, sorry no pics)

    From each A4 cork sheet I first cut from the long side a half width strip with a 45° bevel, then, flipping the cork after each strip, I cut a sheets worth of full width strips (17mm at base) ending up with a strip slightly less than half width (and not always a constant width). Taking one track at a time, the straight sections were measured off first, from the centre board join. Then using the same method as developed on the home layout, I cut then glued the curve underlay strips on the desk top before adding it to the layout. End result visible in pic above.
    [Description of the desk top process is in the 19th post on http://platform1mrc.com/p1mrc/index.php?threads/z-gauge-downunder.1848/page-2]
    Infill sections for the points/turnouts, etc were cut from the 'half' width stock created as each sheet was cut up.

    Next up, adding the top track.

    Peter
     
    Last edited: Feb 19, 2018
  4. Z_Downunder

    Z_Downunder Full Member

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    The next step was to add the base for the top (red) track sections that were in front of the back scene - this was a shaped 50mm wide strip cut from 40 mm styrene foam and blocked up to the correct height. I started from the right side and worked across the two boards leaving undersized gaps for the Märklin small radius bridge sections (grey units pictured below) and the cross over point.

    [​IMG]

    The first non Märklin structure was added where the rising branch line crosses the road at the bottom of the zig-zag road via a lasercut single track bridge kit from eedesignz …

    [​IMG]

    As you can see the rail bridge has been moved around the curve a little, otherwise it would have been hard up against the side of the underpass - the embankment opening was simply made by cutting and sliding the bank along.
    Note : the 3 cyclists in the background are overscale at 1:200 however away from buildings, etc that isn’t noticeable.
    Being overscale probably helps them get up the hill without rising from the saddle :)


    Also the truth of the photo will out - last time I knocked the front railing off the bridge I managed to put it back the wrong way round :facepalm: - another job for the to-do list.

    The design of the track on the left board required a non standard short (19 mm) length of track at the centre front - this was cut from a standard 25mm track (7 sleepers). The required length meant cutting out 1 sleeper so that the new centre two butted up together. The four cuts in the plastic base were done with a craft knife, then the ever faithful Dremel was used for cutting and cleaning up the identical pair of rail/sleeper units before rejoining them. In situ, looks as though the clean up was a bit too thorough …
    [​IMG]
    [This same method was used on the last non standard length of riser track at the front of the home layout fiddle yard. Refer to the 13th post on http://platform1mrc.com/p1mrc/index.php?threads/z-gauge-downunder.1848/ ]

    Sorry, no pics for this next bit : the top track in front of the back scene alignment was laid to check the profile, and after a few minor adjustments made with styrene wedges at the bottom of the support blocks, they and track base were glued down. The undersize gaps at the bridge sites were trimmed to fit the Marklin bridge sections - with adjustments to the base of the central pier on the right hand double span bridge. After marking the cork underlay limits, the loose track, and the bridge sections were removed.

    The back scene boards were cut to shape to clear the base level tracks at the outer edges, and to clear the top tracks where required. After a slot was cut in the base foam, the back scene boards were slotted into place, and the blocks for the ramps up to the left side and down towards zero level on the right were made up and glued to the base sheet only. The top track behind the back scene alignment was put in place to check the profile. A few more minor profile adjustments were completed - being behind the back scene, a thin layer of plaster was used. Once dry, the track sections were briefly returned, the cork underlay limits marked, and the track sections removed again. Finally, the two back scene boards were glued in place.

    The final cork underlay was then cut for this set of tracks, cutting the straight strip into three for the small 145mm radius track used for all the curves and then fixed in place. All the track except the cross joint adjustable track sections was laid down and secured. At this point I had just over 200mm of full width and about 4 strips of half width cork left.

    Next time, the first of the structures on the left hand board …

    Peter
     
    Last edited: Feb 19, 2018
  5. Z_Downunder

    Z_Downunder Full Member

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    I had originally intended to have a level crossing where the road bridge now sits at the front of the left board, however the gradient was way too steep for a main access road. This bridge was kit bashed from four double tunnel portals and their wing-walls.

    Here is a progress pic for one side …
    [​IMG]

    and the almost finished article today …
    [​IMG]
    On the to do list : the stonework colour needs to be evened out &/or toned down, and a street light added on the footpath side at the centre of the bridge.

    The tunnel liner brickwork is taken from a scan of a Kibri single Tunnel liner insert (4 cm wide/deep), and duplicated in image software to give an oversize sheet that was then cut to size. the spacing material and 'road base" is styrene foam off-cuts, while the footpath and cobbled road are eedesignz products. Initially I was annoyed with the dips, however it is a heavily trafficked road, so why not.

    The roads, tunnel portals and the topography (ground profile) were filled in working back from the right board to the left. The two pairs of Busch flashing light sets for the crossings on the top road were also added at this time.

    This early January 2015 pic shows the two boards with the right board topo virtually completed, and the left nearly there …
    [​IMG]
    The early state of the culvert can be seen on the left - those keen eyed readers will note different straw colours, and that the road bridge sticks out to align with the yet to be added facia board. The styrene foam spacer on the road bridge is also visible. The double/single tunnel portals with high head-walls on the left are a Noch product - reduces the actual tunnel length from a track cleaning aspect.

    and two days later …
    [​IMG]
    There has been one change to the road layout from the final plan, with a forestry and farm access track added at the top right. The two main road bridges and the top road bridge on the left board are still styrene based while final structural formats were being decided on.

    With the method of transport to the show still being thought about, no attempt was made at this stage to deal with the under board wiring other than drilling the holes through (hence the wire coils at each point/ turnout, and at the one visible power supply point), nor with a framework to protect it. A primitive but effective set of dovetail boards attached under the MDF and in front of the back scene board holds everything in alignment. Using the bridging tracks also eliminates alignment issues and the need to provide under board wiring connections for each track. Another thing on the to-do list at this point, was to obtain a more suitable support than the somewhat flimsy camping table, especially with extension in mind.

    Next three scratch built bridges …

    Peter
     
  6. Z_Downunder

    Z_Downunder Full Member

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    Having decided on a structure for the three road bridges on the left board, I purchased the parts for them using Christmas ’14 money, and got on with construction. Current detail of the main road bridge over the three rail tracks …
    [​IMG]

    This was made up as a small precast box girder bridge using 3.2 mm x 2mm Plastruct U channels glued to a section of .04 mm sheet. The side panels were cut from an Evergreen 4.8 mm white sidewalk sheet, while the expansion joints were cut from an Evergreen 0.64 mm V-groove sheet, and the railing is a Faller product. The printed roadway and laser-cut footpath are eedesignz products, while another over-scale cyclist fits the scene in isolation.

    Underside view …
    [​IMG]

    The short skew bridge with two footpaths takes the main road over the stream - this is the same construction as the bridge over the rail-tracks with an extra box section for the extra footpath, and a little more work to get the skew right …
    [​IMG]

    The final bridge on this board still has the box girder underside, and bridge rails, but no side panels and a plasticard concrete footway on the side nearest the back scene, with a section of Busch roadway to complete the topsides view.
    [​IMG]

    The central support is based on the cylinder made up with the offcuts from the skew pier in the Oil Depot on the home layout
    [See the inset in one of the pics in the 13th post on http://platform1mrc.com/p1mrc/index.php?threads/z-gauge-downunder.1848/

    Then an upper support structure of box sections was scratch built from two U channels, with sheet styrene end-caps.
    [​IMG]
    Must have a slide bearing, as it appears to have moved off centre slightly. :twitch:

    Next, the major step of expanding the layout …

    Peter
     
    Last edited: Feb 19, 2018
  7. Z_Downunder

    Z_Downunder Full Member

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    Onwards and wider ...

    Having gained access to a couple of 60 x 40 cm MDF laminated boards late in 2014, and holding enough track & building stock, the plan was revised, yielding the current layout, with the exception that the two pairs of track switches “X” were added between the 2016 and 2017 WA exhibitions, for reasons that I’ll get to at the appropriate point. A single laminated MDF shelf was ‘butchered’ to provide the link for the fiddle yard tracks, and a control area.

    [​IMG]
    The pale blue boxes are the isolation sections for the train change over - in accordance with the European standard, the outer track is anticlockwise running, and the inner clockwise. The branch single track operates in either direction &/or onto the elevated track.

    The first thing done was to send off another direct order for additional 1.5mm cork sheets to create the underlay for the expansion. The one short length left over from the first order can be seen on the top track of the new centre board in these next pics which show the state in mid February 2015, with the completed bridges in the foreground (trees, etc were yet to even be considered) …
    [​IMG]

    So while waiting for the cork, work on building the top track link began. To align with the back scene on the side boards, the centre back scene board sat on the top of these new base boards, so some temporary brackets held it in place on top of the boards (sorry no pic).

    [​IMG]
    The wide gap between the two centre boards at the back on the back scene board has since been plastered closed - masking tape being used on the back board for the obvious reason that they needed to be separated for maintenance & transport.

    This next pic is slightly blurry, however it does give a slightly more front on view, a thin styrene support sheet was glued to the back board, the height set such that the top of the sheet resting on it would be at the 80mm level - the 50x40 ramp track support leading up to it can be seen on the right …
    [​IMG]
    The arrangement of the triangle between the two roads and the tracks in the foreground has since been changed. While an early plan for this centre section had the top road running parallel to the rail track, in this final plan with the top track located further back, it was turned into the back scene at each side via a pair of tunnels. More on that in due course.

    The Station Building and island platform sections are by Kibri, the island platform parts acquired in a job lot, about 8 months before a reasonably priced matching station kit became available (US$26) [retail when originally released down-under ~AU$75+]. It had been sitting un-assembled in it’s box for over twelve months waiting for a board to sit on.

    Now clearly SWMBO wasn’t going to stand for me using the spare bedroom as a work area, nor was our one car garage an option, so it was off to Bunnings, who just happened to have a trestle table on special. When I got there, I found they also had a folding version, although more $, that was an even better option storage and transport wise...
    [​IMG]

    and newly opened, join barely visible …
    [​IMG]

    Next, finishing the centre section, and adding the base frame.

    Peter
     
  8. Z_Downunder

    Z_Downunder Full Member

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    At this point I started referring to the boards by number on my to-do lists, so #1, #2 & #3 from left to right & #4 for the Control deck & centre section of the fiddle yard.

    So on the new centre board #2, once the top track base was completed, I dug out the second stream and constructed a culvert under the railway area, similar process to the one on board 1, except this one was straight through, so with no bend, no need for a manhole cover - current pic …
    [​IMG]
    There is a double isolator between the top two tracks (separate controllers), while the single isolator on the bottom track the start/end of the station stop first/last control section - depending on direction of travel.

    A 4 barrel box culvert was scratch built from Plastcard to take the stream under the main road, again a current pic …
    [​IMG]
    With the buildings removed for transport/storage, one of the house lights is revealed on left - the same globe is used in the original Marklin Z signals, and the locos. More recently, LED lighting has been introduced.

    With the arrival of the extra cork, the underlay and tracks were then completed on this board, using the new table for support.

    Now came the time to get on with the support frames, the fascia boards and the electrics, as I was still acquiring some of the points and one track switch for the Fiddle yard connections on board 4. The outer frame of end boards 1 & 3 was made up with 20mm x 12mm pine, then the whole edge was covered with fascia boards from the same stock as the used on the home layout. This was easy on the back & front, however the side sections which also covered the rising scenery required a bit more work. They were cut slightly over size, then sanded down - the cantilevered sections minimise the length of tunnel track to access for cleaning purposes. Current pics …

    [​IMG]
    Board 1

    [​IMG]
    Board 3

    The edge between the boards was left with just the dovetail pieces until the electrics were finished - I’ll get on to that next time, which will also allow coverage of the supports on those boards - got to dig out some details from one of two external drives…

    Peter
     
  9. Kimbo

    Kimbo Staff Member Moderator

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    Peter, having seen the end result of this layout build, it’s really interesting to see how the development of the layout took place.
    :thumbs: great work and a great read
    :thumbs: popcorn ready for the next instalment. Kim
     
  10. Z_Downunder

    Z_Downunder Full Member

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    Kimbo wrote:
    Thanks Kim. O.K., you might not need too much popcorn, as I’m still digging for the electrical spreadsheets - I know I didn't bin them. [​IMG]

    Meanwhile here’s an update on where the layout was in mid January 2016 with just under 6 months to go to the exhibition. Sequential views of Boards 1, 2 & 3 with a try out of possible house locations, then the view of board 4!

    [​IMG]
    Board 1 : most progress here - underboard electrical connections done. Additional supports have been added to the top railway bridge. The two houses front right are complete including interior lighting, the mini-golf course has been added in the front corner and has playing customers, while the triangle between the roads and rail has had a retaining wall added and after back fill, a pub added.
    In all there are three places to imbibe - this pub, a bar in the station building, and the “Ratkeller” by the right side of the stream at the back of board 2.
    [​IMG]
    However the top road still needs attention, as do the approaches to the original single lane cobbled road bridge at the stream. Then there’s the general issue of vegetation, this point applies across the whole layout.

    [​IMG]
    Board 2 : all underboard electrical connections done, apart from the station stop connections. The bar at the station is at the left end. The two top road tunnel portal entries are sort of visible in this pic, the road surface still needing attention. The issue of the old road across the stream still has to be resolved, as does the paving of the old road beyond the cobbled sections at each edge. More ‘security’ fencing is required between the road and the goods shed access on the right of the station.

    [​IMG]
    Board 3 : all underboard electrical connections done. Here the underpass has lost its railings - they’re pinned out of the way on the unfinished hill top. The main road sections while laid out haven’t actually been cut to size or fixed in place. and work is required on the zig-zag road. While additional supports have also been added to this railway bridge, the servo/garage is still sitting in a ‘greenfields’ site. The rail crossing barriers and attendant’s quarters also have to be dealt with.

    [​IMG]
    Board 4 - the bit in the middle - they say a picture is worth a thousand words - nothing on top & nothing underneath. Oh, and did I mention an upcoming six week visit to the UK after Easter that year. [​IMG]

    Going back to the tunnels, these have white walls, black roof & road surface, and are lit with Faller platform lights. A removable panel in each tunnel roof allows for replacement of blown globes - the back scene panel has cut outs to allow access. The power supply comes up from under the board in plastic straw conduits (the cables for the Viessmann controllers were a later addition) …

    [​IMG]

    Next time, nearly ready to go, then definitely the electrics after that, as the grey cells finally clicked, and I know where the [​IMG] spreadsheets are - still need to turn them into an image.

    Peter
     
  11. Toto

    Toto I'm best ignored Staff Member Founder Administrator

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    Wow ..... What a build. I've only had a quick glance through your thread at the moment but it looks amazing. I'll read it through thoroughly tonight.

    Great coverage of the build. A fantastic thread. :thumbs:
     
  12. Z_Downunder

    Z_Downunder Full Member

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    Toto wrote:
    Thanks Toto.

    Now while things progressed, including final acceptance of the layout at the end of March for the 2016 exhibition, one item that I was asked to fix was the bare ply of the back scene. That was in hand, however it had to wait until I got back from the UK trip with these …

    [​IMG]

    [​IMG]
    There’s the Scottish genes kicking in - a lot cheaper in UK without postage added in. :)

    I also came back with an additional Märklin Z 240V controller, that I’d bought on eBay, and had sent from the US to my sister-in-law’s home - as they weigh in at 1.3 Kg - just under 3lb, a saving of US$30 on the freight charges to home. The seller having taken the Pitney Bowes option, it did have the advantage of being able to watch its 9 day journey from California to Devon via Kentucky & Derbyshire !!

    So a final sequential scan across the front boards three days before the 2016 exhibition - for board 2, the pic was taken mainly as a guide to building placement …

    [​IMG]
    Board 1 : temporary surface applied to top road [“Top Coat” from Woodland Scenics], a few more trees, although the willow trees are yet another cautionary eBay tale. Every tree bulk purchase up this point had been delivered unscathed in boxes (where they remained at this stage of construction). This seller was looking to cut costs, so sent them in a plastic satchel. Needless to say I received a bag of foliage and bare tree trunks - a single email with pics brought an immediate 50% credit. Fortunately a brushing of PVA glue and a roll in the foliage debris produced sufficient trees for my immediate use. Both the stream on this board and on Board 2, have had a rippled plastic surface added.

    [​IMG]
    Board 2 : right hand station ramp now fenced off, and a Tourist Bureau placed next to the station, with a hedge & fence on the wall above the stream. The area before the next house has been turned into a small park, then the parsonage next to the church finishes off the front row of buildings. The back two rows of houses have simply been left in-situ to fill the space, while the back road across the stream has been removed.

    [​IMG]
    Board 3 : the underpass railings are back in place, and the hill top has been capped. The main road and the zig-zag road have been completed to a reasonable state, as has the garage/servo and rail crossing barriers and quarters. I ended up cutting the barrier mechanisms off the supplied base and planting them on the edge of the road - the second one is just off to the right of this pic. The pins are still in place holding the recently glued fence sections, while the bare plaster was painted earth brown later in the day, turning it into a building site. The top road surface still needed to be finished inside the tunnel, and the top left hand crossing needs to have the road surface infill between the rails.

    Board 4 : I don’t seem to have taken a pic of the fiddle yard and control board at that time, so this current one with have to do.
    [​IMG]
    All under-board electrics completed - including the extra wiring for the station stop power supplies. As noted earlier when I posted the plan of the extension, only one pair of track switches was installed for the 2016 exhibition, those marked ‘X” were added before Easter this year, otherwise as a fiddle yard/control deck, that’s was it.

    The two outer controllers are set and forget for the two automated mainline tracks, while the inner ones are for the branch loop & top line operators. The two switches with red Dymo labels in the centre allow for the total isolation of the blue isolation sections for each mainline direction - normally off before starting a session, and also off when swapping trains around. The relay to the left with red label is the one for the top crossing lights - labelled as a reminder to check it was off at system start up.

    I’ve now turned the electrical spreadsheets into an image, so more on the electrical side next time (and on the new site).

    Peter
     
  13. Z_Downunder

    Z_Downunder Full Member

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    No layout is without it's electrical wiring, and analogue even more so. An initial calculation showed the most connections I needed from the other boards to board 4, was 33 for board 3. I had sourced some 32 pin PCB connectors from Alltronics, and set about connecting everything through them.
    [​IMG]

    So I set up several spreadsheets (the original file has been what took a bit of finding). One sheet for the inter-board connections and another two for the control area - of these, one for the switches and the last one for the relays …
    [​IMG]

    The two left hand sheets cover the relays and switch banks on the control deck. The right hand spreadsheet covers the connections from Boards 1, 2 & 3 through the 32 pin connectors, and then the final quarter covers the connections to the points and track switches on board 4.

    So lets go underneath - Board 1 is the cleanest …
    [​IMG]
    Most of the wire used was salvaged from a 5+m length of 30 pair telephone cable, that had been replaced on a job site I was on years ago. Quite a bit had been used on the home layout. The Yellow power wire is either Märklin or Brawa. The red boundary marks the fine wire that all the LED signals are supplied with these days. With the overall layout being a bit longer than the trestle table, and the top batten (out of shot) being mounted on top of the dovetail shims, the internal edge support has also been mounted on spacers. The wire holders are cut from either 12 or 25 wide units bought in bulk as a job lot for minimal $.
    The black strip around two edges is the hooky part of a velcro strip for mounting the black curtain, and I'll explain the holes at the bottom right in due course.

    Board 3 : Here the top (connecting edge) batten is visible, as is the edge connector. The Board 1, 2 & 3 connectors (all female) are mounted so the face is level with the edge of the board. There is also a tight fit cut-out in the batten over each connector (out of view in previous pic).
    The same note for board 1 applies re the velcro and the holes at the bottom left this time …
    [​IMG]
    Due to the track switch connections for the road crossing lights, I needed 33 lines from this board to board 4. Mounting the relay on Board 3 wouldn't work, as the other switch was on board 2, so the same number of connections would still be required. The solution was to put the only lit building on board 3, the church, on the same circuit as the street lights.
    The controllers for said crossing lights are mounted under the board - not recommended by the manufacturer. In practice over a three day show, there seems to be enough air circulation for them not to activate the thermal overload. Being eBay purchases, there are two different vintages and thus sizes. The newer (cheaper) controller set was installed first with the wires for the lights on one side of the crossing going under the tracks, then down plastic straw conduits through the void below. Separate straws were used for each of the four lights in the older controller set (cheaper than other newer ones), which arrived and was installed later. Much less messing around making sure the right pairs of wires were connected (in series), to get alternate flashing diagonally i.e. left nearside & right far side then vice versa.

    Board 2 is less neat, as by the time of this photo with literallly days to go, the red control wires for the Viessmann boxes had just been added …
    [​IMG]
    The battens here are positioned to support the centre join between the two boards, plus a third along the front edge for the fascia - it is partially visible at the top. The velcro has a gap in it, due to the Viessmann control wires being on the outer rail. Only one dovetail shim was used each side, nearest to the connector on the side board.
    I will need to get another terminal block once all the house lights are in, to replace the circled plug only connections.

    While the grey auxiliary power returns for each of the four controllers are inter-connected, boards 1 & 3 only have one auxiliary yellow power circuit each, connected to the nearest main-line controller. Board 2 splits the load between the two inner controllers - the points on board 4 are similarly split. As the Viessmann controllers are mounted on the back of the back scene, their cabling runs down straw conduits on the front side inside the scenery - the ones which were initially installed to take the road tunnel light cables. This allowed me to get way with only having 32 pins available on the connector, as the power supply to the Viessman controllers has to be from the related track controller. Hence the two extra yellow wires on the right of the connector. As a precaution, with pins available, extra grey return wires were run direct from the Viessmann controllers as well.

    Each of those three 32 pin connectors connects to board 4 - Spaghetti Junction in Birmingham was doddle to negotiate compared to this lot …

    [​IMG]
    The blue lines show how the board was made up from a standard shelf - the centre block came from the edge "x". Before joining, the edge melamine strip was removed along edge "y", and partly reused along the sides of the wider control deck (as bought, the edge strip only ran along one long side of the shelf).
    The battens are mounted, such they are a tight fit to the back batten on board 2 - the variation in screw spacing is to reinforce the joins of the cut shelf. The board connector mounting brackets were cut from 1.5 mm thick steel right angle brackets - highly unlikely to bend even though the male connectors stick out over the edge of the board - I think the plastic connector might break first. The holes in the brackets are slightly oval with the long axis parallel to the board i.e. horizontal. The mounting bolts being only finger tight - makes slotting the boards together relatively easy. The joining sequence starts with 4 into 2, then after trail & error, 3 into 4 and 1 into 4 - this last one is always a :bleep6: but less so than doing 3 into 4 last.
    The isolation gaps for the train swap are in the inner rail, ensuring no conflict with the station stop circuitry.

    And an under board schematic showing how they fit together …
    [​IMG]

    In summary, for all the complexity, when all the boards were connected together, I had just 5 short circuits on board 1 to fix, four on board 3, and two on board 2. Nothing like a buzzing solenoid to get the grey matter working.
    The ones on board 3 were same as board 1 - tut-tut hadn't followed the spreadsheet. :facepalm:

    Up next, ready for the off.

    Peter
     
  14. Kimbo

    Kimbo Staff Member Moderator

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    :faint: amazing Peter, last pictures had me choking on me pop corn !!

    I think you would make a great telephone engineer :avatar:
    :avatar::avatar:
     
  15. Z_Downunder

    Z_Downunder Full Member

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    Kimbo wrote:
    Sheesh Kim, I thought that was un-seasonal thunder down south last evening :avatar:

    O.K. a couple of pics taken before the 2016 show …

    [​IMG]
    In the left background are Kim & co setting up Lord Street Depot.

    At this point to me at least, the board joins up the hills stuck out like sore thumbs, so I got down to some last minute tree planting. I also had time to add a pine plantation at the top of board 1 to get a better flow into the back scene …
    [​IMG]

    All covered up (Queen Double sheet) and ready for the off …
    [​IMG]

    A note on the automatic running as it was set up originally :
    The two trains for each circuit start off with the locos in the blue isolation area and with the cut-out switch open. After setting the controller to the correct speed, on closing the switch, the train on whichever track was live departs, and a couple of track lengths later on the single track, the loco passes over a track switch which simply turns off both tracks in the blue box. On completing the circuit the train re-enters the fiddle yard, and passes over the track switch installed at maximum train length from the entry point/turnout. This switch turns on the power in the opposite track only at the blue box, releasing the other train, at the same time it changes the entry point/turnout to that opposite track as well. In theory the process repeats ad infinitum - more on that next post.

    Peter

    P.S. Another note : re size/space - to build this same layout (excluding the control deck area - i.e. assuming DCC) at 4mm requires ~6m x 2.4m or ~20' x 8'; and at 7mm ~10.5m x 4.2m or ~35' x 14'
     
  16. Z_Downunder

    Z_Downunder Full Member

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    With help from #1 daughter and #1 grand-daughter, we finally exhibited for the first time at the AMRA WA show. Some gremlins got in on the organisation side, while we had exhibitor passes and an exhibition space, no stand number had been allocated, and the layout notes hadn't made it into the program. :whatever::whatever:

    So from day one - that being my 70th birthday ...
    [​IMG]

    We had major problems with some of the track switches leading to periodic fiddle yard crashes throughout the three days of the exhibition. The ones for the train swapping were releasing the other train, but not staying closed long enough to change the entry point/turnout. Consequently the two trains were ending up on the same fiddle yard track. Crunch.
    The other was with the exit track switch on the inner track on board 3 - it just wasn't working every time, so the incoming train wasn't stopping. Crunch again. This I fixed before opening on day 2 by fitting a replacement from stock.
    Also had no express train running due to non-arrival of the switch box which would have allowed the override of station stops.
    Although, when I can sort it, the video does show some "non stopping" trains on the branch line loop ! :facepalm:

    Two assistants and two automated tracks meant there were opportunities to chat …
    [​IMG]

    As already mentioned, we have quite a few videos (of iPhone3 vintage) which I'm still trying to get into shape, so here are a couple of the still pics taken, to go on with ...

    [​IMG]

    and the girls hard at work (taken while their trains were stationary, so allowed to look up :)) ...
    [​IMG]
    Pic also shows a fully operational Lord St Depot in background, and a size contrast of Z vehicles versus the 1:25 R/C trucks (lorries/HGVs) behind. From memory the youngster on the left hung onto the railing for quite a while.

    One thing that we had to deal with that rarely occurs at home, was the electro-static black gunge build-up on the tracks generated by the viewing public - forewarned by notes on another blog, a box of cotton buds was kept on hand to quickly clean up.
    The Trix/Märklin N/Z wheel cleaner proved its worth keeping the loco wheels clean ...
    [​IMG]

    Then there was the scenery side of things - while relatively bare, the small number of "Can you find ..." questions which we put out for days 2 & 3 were well received.
    [​IMG]

    Before the final day opened, we were surprised, gratified and encouraged by gaining 3rd place in the Class 24 (under 24 sq ft) section.
    [​IMG]

    So what needed to be done for June 2017 - well operationally, firstly sort the fiddle yard track switch issue, then once it was delivered, I had to install the switch box to allow through running at the main line platforms.
    Next thing was to slow down the approach/departure speeds on both the automated tracks outside the deceleration/acceleration sections at the station to get a more prototypical speed. The entry speed setting needed to get the locos to continue through the braking section is way too high for the open track, as will be seen when I have sorted the videos.

    OK, back to work on them.

    Peter
     
  17. ianvolvo46

    ianvolvo46 Staff Member Moderator

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    Great report and photos Peter for all the gremlins it looked to be fun and well done to you and your team on 3rd place.

    Ian vt :thumbup::thumbup:
     
  18. jakesdad13

    jakesdad13 Staff Member Moderator

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    ianvolvo46 wrote:
    Hear hear :thumbup:. And a belated happy birthday Peter :tophat:

    Cheer's, Pete.
     
  19. Kimbo

    Kimbo Staff Member Moderator

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    Hi Peter, we had the same problem as well with dirty track, couldn't understand why we had problems with a few locos till one of the organisers said that the “ local conditions” caused dirty trackwork. I didn't get chance to look at your layout very closely that year because of operating duties. My memory of that show was the constant drone of the rc trucks, I don't think any one realised we were operating Sound locomotives!!
    I must get round to up grading my assistants, your assistants are a lot nicer looking than my mob ! :avatar:
     
  20. Z_Downunder

    Z_Downunder Full Member

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    Thanks Ian and Pete - it was all a learning experience for our first go. :thumbup:

    Kimbo wrote:
    Kim - "thank you kindly" from the girls. :)
    You're not wrong about those trucks last year. SWMBO took earplugs for days 2 & 3. We were very happy when they went off on their circuits of the exhibition each afternoon - a few minutes reprieve.
    We had no problems noise-wise this year when located at the opposite end of the exhibition space, other than that rowdy mob next to us :avatar:
    [see post 4 at http://platform1mrc.com/p1mrc/index.php?threads/2017-perth-model-railway-show.1786/ ]

    However still the same issues with the black gunge. :whatever: Which, I guess, is a prompt to get on with reporting the changes/upgrades for the exhibition this year - coming up shortly.

    Peter
     
    Last edited: Feb 19, 2018

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