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T O P I C    R E V I E W
AVRR-PA Posted - 05/16/2009 : 6:57:04 PM
Hi, everyone --

A friend is building some modules or layout sections for a client and sub-contracted the basic module construction to me.

The specifications are a bit unusual but I wasn't told why - "Theirs not to reason why, theirs but to do and die..."

It has been an interesting little exercise and I thought you might like a quick overview.

Moving on, to avoid the "can't edit" problem.

Don
15   L A T E S T    R E P L I E S    (Newest First)
TmOn30 Posted - 11/08/2011 : 05:47:37 AM
Hey Pat Hope this Helps. http://members.westnet.com.au/mjbd/html/aluminium_framing.html

Where's "M"

Tom.
danpickard Posted - 11/07/2011 : 10:24:13 PM
Pat,
I believe Mario is doing a website rebuild/clean up, but don't doubt he will have the aluminium framing info online again in the near future.

Cheers,
Dan Pickard
belg Posted - 11/07/2011 : 9:27:28 PM
Thanks for the info Don, I'll try the scroll saw next time for a pattern.(Makes good sense go slower and stay close to the line and finish sand with a spindle sander) Waiting for the Mario to respond I'm thinking he might be traveling. Tried several searches but have not come up with the right term to find it. Pat
AVRR-PA Posted - 11/07/2011 : 8:56:43 PM
quote:
Originally posted by belg

Hey Don, I know this is an old thread but I was wondering how did the rest of this project turn out? Also I don't see any pockets for legs, was this going to be mounted on the wall or shelves?
If you could can you share how you made the router template for the waffle effect. I assume you drilled the 4 corners and then connect them with straight cuts but I have had bad luck getting a template like this to come out smooth, I always get the straight cut just off and then are not smooth. Thanks Pat

PS Do you have a link to the thread Mario where is discussing his aluminum frame modules?


Hi, Pat --

You're right about no leg pockets. The owner sets up his modules on tables. Seems wierd to me, but as I mentioned earlier in the thread, I never found out who the ultimate customer was or why he wanted them built this way.

I still haven't built the light-weight corner/transition modules. I got involved in other projects.

But I did apply the "technology" to build the Wye module for the FreeMo group. That worked pretty well. They do have openings for legs, which bolt on to the ends, like most other FreeMo modules.

My shop partner, Garth, is really good with his scroll saw and he just followed the lines to make the pattern I used for routing.

When I made the wye, I decided against doing all the cutting with a router. I first cut to within about a 1/4" of the line with a saber saw, so the router didn't have to work so hard.

No, I don't have a link to Mario's thread - you might try Rick's Google Trick - or just send a message to Mario.

Don
belg Posted - 11/07/2011 : 6:52:20 PM
Hey Don, I know this is an old thread but I was wondering how did the rest of this project turn out? Also I don't see any pockets for legs, was this going to be mounted on the wall or shelves?
If you could can you share how you made the router template for the waffle effect. I assume you drilled the 4 corners and then connect them with straight cuts but I have had bad luck getting a template like this to come out smooth, I always get the straight cut just off and then are not smooth. Thanks Pat

PS Do you have a link to the thread Mario where is discussing his aluminum frame modules?
AVRR-PA Posted - 05/20/2009 : 09:22:37 AM
Hi, everyone --

Thanks for all the encouraging comments!

Before I left for NYC, I laid out two 30 degree transition modules, one for each end of my dual-gauge FreeMo module. I'm going to build one of them fairly soon, using the methods I developed for the client job. I'll add to this thread as I work through this new project.

If I can, I'll make the two modules symmetrical, so I can make all four waffle sections in one operation. (I'm going to waffle the deck as well as the bottom.)

Yeah, yeah, I know the verb "to waffle" has a rather different meaning in sandard useage.

Don
George D Posted - 05/19/2009 : 09:58:57 AM
I’m just catching up with this, Don. I’m familiar with the Sipping and Switching Society’s modules, so it’s interesting to see a craftsman use their ideas. I have a switching module in the back of my mind and if or when I get started, I’ll be following your method. Thanks for taking time to post this great info.

George
Red P Posted - 05/19/2009 : 09:42:42 AM
WOW, those are impressive.
Ive been trying to figure out how to do light weight benchwork, not really modules but sections that will become a larger layout later on.
You have given me some good ideas.
P
Mike Hamer Posted - 05/17/2009 : 5:55:31 PM
Great looking modules, Don. With all those constraints facing you, you hit a real "home run" once again. Brilliant effort!
rfmicro Posted - 05/17/2009 : 4:22:47 PM
Don,

Good project and well done. I am in a similar position building 3' X 4' modules made of 0.75" X 3" sides and longitudinals with 0.25" luan top and 1" pink foam for the top. 2" X 2" wooden legs with braces and levelers of course. I have one built with a lower level for a two tier module. I may add on a third level someday. I find the module very stable and even more so with additional modules attached.

I did submit a bid for an aluminum equivalent (per Mario's web site), but it came in >$400.00 for one module and that seemed a bit over the top; hence, back to the light weight design. I needed a light weight design that was modular such that I can move it should I need to, and for ease of building the layout without having to worry about whether I could reach all areas or not.

Regards,
Trent Mulkern
Mechanicsville, MD
Peterpools Posted - 05/17/2009 : 09:35:01 AM
Don
Couldn't ask for more. Just a great tutorial on how to do it right> Thanks for taking the extra time to document each step. As I am getting ready to move my small switching layout into another room and add an extension to, I've picked up quite a few good tips to follow.
Peter
BCT
AVRR-PA Posted - 05/17/2009 : 09:06:23 AM
quote:
Originally posted by MarkF

Nicely done Don! I've seen the Sipping and Switching Society's layout in person and can attest to the quality of their construction. A novel approach indeed! I tend to think that overall, we model railroaders over build our layouts as it is. A lot of lumber to hold up very little weight. This approach is very practical.


Hi, Mark -- thanks for writing!

One important difference between these modules and the S&S modules that I forgot to point out: no legs. I don't know why the client specified no legs - perhaps he sets up on tables or saw horses. But that did mean I could eliminate some of the material (and weight) that would be needed to attach legs.

If I were building a home layout, I'd at least consider this type of benchwork.

On the other hand, the benchwork that I helped Vagel with was built with some different requirements. Specifically, it's intended to function as a work bench for a year or two, until we get around to phase two; it's intended to support our weight if we need to get up on it while working on the layout; and it's designed to allow a couple of guys to stand on it while working on the lights over the layout.

Different needs, different solutions - that's what makes artisanship interesting.

Don
AVRR-PA Posted - 05/17/2009 : 08:56:26 AM
quote:
Originally posted by Neil M

Hi Don, i'm impressed with the neatness of your framework. It should be very stiff.

I was just wondering - was there a reason that you didn't use aluminium in place of a wood frame to save weight? Our Australian members seem to have done that on lightweight modular layouts with success.


Hi, Neil -- nice to hear from someone in the old country. (Three of my four grandparents were Irish immigrants.)

Aluminum? That's one of them metals, right? Never touch the stuff.

Actually, I guess the honest answer is that the job had to be done quickly so I used the materials on hand and the methods I already know. Using aluminum in place of some of the wood parts would, in fact, be interesting, especially since West Systems will join aluminum to wood with enormous strength.

Thanks for starting me thinking.

Don
AVRR-PA Posted - 05/17/2009 : 08:51:07 AM
quote:
Originally posted by Vagel Keller

Don, this is a wonderful exposition on the argument that model railroading, truth be told, is much carpentry as it is playing with trains!

Vagel


Thanks, Vagel.
AVRR-PA Posted - 05/17/2009 : 08:49:20 AM
quote:
Originally posted by hunter48820

Wow Don, I'm impressed. You do beautiful work. Definately passed the butcher stage that I am still in! Thanks for the great thread and details of the construction.

By the way, I might have just missed it but what was the final weight? Just looking at all the material, it looked like it would have been over 10 pounds.



Hi, Andy --

I don't actually own a scale that's intended for weighing in that range, so I used the "weigh your dog" approach - I weighed myself on the bathroom scale and then weighed myself holding one of the larger modules. They came in about 11 pounds -- good enough, according to my customer.

Places where I could save weight in the future:
-- waffle the "deck" piece; that would also make it easier to run track feeders since you wouldn't have to drill, just poke a hole in the foam.
-- use thinner stock (3/8 or 1/2) for the ends instead of 3/4".
-- use 1/4" luan instead of 3/8" plywood for the longitudinals.
-- only apply one coat of paint.

I need to build a couple of FreeMo transition modules; one to use between my dual gauge module and Vagel's and one to allow me to run the standard gauge track off in a curve to start another branch of the FreeMo setup. I think I'm going to build a transition module with this new "technology" and see how it goes. The 6" height of a FreeMo module should make the whole thing even stiffer.

Don

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