Laser-cut plug track now on the baseboard - and engine-release turntables

Hi everyone,
I've been a bit absent recently. I've had my head down laying some track and trying to ascertain what the difficulties might be in laying laser cut plug track in a layout setting.
I've been working on my S4 challenge project, working with just the baseboard tops to begin with. I'm sure there are those who will say I should have built the complete baseboards before laying track, but there are several reasons for progressing this particular way, more of which later, but for now I thought I'd share my progress.
I must stress that at this stage, I am just testing out some ideas, and I'm happy to take all of this up and start again if need be, but so far so good. Stock all runs well (as far as I can test at this stage).

I found the assembly process really enjoyable, the major plus being being able to temporarily fit track to ensure alignment between timbering bases before gluing down, and also across baseboard joints. Everything I have laid here is removable, so very easy to go back and replace parts as required.
I've found that filing down some short lengths (40mm) of rail such that they fit into a chair socket useful. The help to hold a long rail length in place whilst chairing, especially on a curve. Other than that everything else has been pretty much to Martin's words and music.

There is still some fettling to do, but I hope this provides some inspiration for others to try.
Given that this layout will be exhibited (I hope), I've been experimenting with different methods to ensure reliability and hopefully eliminate damage to sensitive areas such as the common crossings and check rails etc. To that end I've played-around with various bits of nickel silver bonding strips, and brass pins soldered under the check rails to restrict movement. They look a bit crude at this stage, but everything is rock-solid. I've found that I can grind the protrusions away quite nicely so they should be pretty inconspicuous when complete. Of course, had I used FDM timbering then I would have incorporated Martin's neat little solution of the restraint wires.
I've packed it all away now as I've had enough of track for this weekend, but next time I'll get some more detailed photos.

I've also built the well for a 50' Cowan's turntable, and used plug track chairs for the race rail.

The TT well and its motor are quick-release, being held by thumbscrews.

 

[Phil O]

James,

That trackwork looks fantastic, it just flows. Have you put anything on the Scaleforum site?

 

[James Walters]

Thank you Phil, that's very kind, but it's still a work in progress. There are three boards in total, which when laid out together do flow nicely. I've tried to avoid straight sections as I like the look of stock trundling around a curve.
I've not put anything on the Scalefour site yet, 'still plucking up the courage.

 

[Steve_Cornford]

Well done James, very impressive!
And well done Martin for providing the Plugtrack facilities!
I can't wait to see some switch blades moving under their own steam!
Steve

 

[Martin Wynne]

@James Walters

Hi James,

That's looking great!

Is that all done with loose jaws? Have you soldered the vee rails in situ at the nose? Using SMT paste? Did you make some FDM filing jigs?

I've found that filing down some short lengths (40mm) of rail such that they fit into a chair socket useful. The help to hold a long rail length in place whilst chairing, especially on a curve.

Can you clarify what you mean there?

cheers,

Martin.

 

[James Walters]

HI Martin,

Thanks!
Yes, all done with loose jaws. Including the slide chairs - I can't have been thinking when I exported those files.
The vee rails are soldered. My paste was a little iffy, so I tinned the parts before assembly, then sweated them together in situ. The chairs seem very resilient to heat which is a plus.

I didn't use FDM filing jigs simply because my FDM printer is rubbish - simply terrible. I hope to get a Kingroon printer soon so will get some jigs printed.
My printer has all sorts of hardware issues, which the manufacturer acknowledges, but refuses to fix. I've given up tinkering with it. It's fine (sort of) for coarse stuff but will not print fine layers without jamming. It has a banana bed too which doesn't help.

Here's what I meant by the filed down bits of rail:

They're useful for holding the rail vertically whilst inserting the loose jaws, a bit like a podger. 'wish I'd polished them up now before taking the photo.

 

[James Walters]

Well done James, very impressive!
And well done Martin for providing the Plugtrack facilities!
I can't wait to see some switch blades moving under their own steam!
Steve

Hi Steve, and thank you.
It shouldn't be long now before they are operational. I intend to use a mk 2 version of my servo actuator, with a modified slider which allows for gauge adjustment:

The base boards have pre-fitted fixings, so the units will simply screw into place and be very easy to replace should a failure occur at an exhibition.

And yes, well done to Martin for making this all possible. I couldn't have done any of this without Templot. Every day I learn something new and am staggered by its brilliance. Using Templot has become my favourite hobby.

 

[Phil G]

Hi James,
I agree with all other comments that does look fantastic. well done, just one question is the vee right after the TT prototypical?
cheers
Phil

 

[James Walters]

Hi James,
I agree with all other comments that does look fantastic. well done, just one question is the vee right after the TT prototypical?
cheers
Phil

Hi Phil, It's sort of prototypical.
My challenge entry will be Midland themed, but I couldn't find a Midland prototype for what I need to fit in the space, so have gone with a LNWR prototype from Harbourne.

 

[Phil G]

Hi James,
A prototype for almost everything!
You amaze me, how you keep finding all these little details. how on earth did you find that photo?
cheers
Phil

 

[James Walters]

Hi James,
A prototype for almost everything!
You amaze me, how you keep finding all these little details. how on earth did you find that photo?
cheers
Phil

It's from the disused railways site, (I asked for permission to use it).
For context, here's how the baseboards are shaping up, the wagon hoist has been shoved along to the end adjacent to the turntable. I anticipate this layout being viewed like a peninsular from both sides, with hopefully the best view from the end, through what will be a narrow iron gateway with a view along the snaking tracks.

Best,

James

 

[Martin Wynne]

HI Martin,

Thanks!
Yes, all done with loose jaws. Including the slide chairs - I can't have been thinking when I exported those files.
The vee rails are soldered. My paste was a little iffy, so I tinned the parts before assembly, then sweated them together in situ. The chairs seem very resilient to heat which is a plus.

I didn't use FDM filing jigs simply because my FDM printer is rubbish - simply terrible. I hope to get a Kingroon printer soon so will get some jigs printed.
My printer has all sorts of hardware issues, which the manufacturer acknowledges, but refuses to fix. I've given up tinkering with it. It's fine (sort of) for coarse stuff but will not print fine layers without jamming. It has a banana bed too which doesn't help.

Here's what I meant by the filed down bits of rail:
View attachment 8765
They're useful for holding the rail vertically whilst inserting the loose jaws, a bit like a podger. 'wish I'd polished them up now before taking the photo.

View attachment 8766

@James Walters @Steve_Cornford

Hi James,

Thanks for the explanation.

Steve suggested using cocktail sticks for that purpose, and they work great.

cheers,

Martin.

 

[Phil G]

I had just found that site myself when your reply came in. Still how on earth did you think to look at that site for inspiration? was it hours of on line searching?
Anyway its all very cool, as is your conceptual drawing by the way.

Out of interest have you figured out how your going to attached the second set of tie bars for the switch blades? Assuming your first set are connected to your modified servo drive as you mentioned in your post to Steve.
cheers
Phil,

 

[James Walters]

I'm afraid I have done hours of searching to find obscure little details.
The jury is still out regarding the stretcher bars. Not sure whether to stick with an REA type for which I'd use an etched kit, or do something a little more 'Midland'. I will be using Midland style rodding so I guess it will be of a Midland round bar type. Exactly what, I don't yet know.
Best,
James

 

[Martin Wynne]

Hi James,
I agree with all other comments that does look fantastic. well done, just one question is the vee right after the TT prototypical?
cheers
Phil

@Phil G @James Walters

Hi Phil,

It's quite a common arrangement to have a V-crossing in the approach tracks to a turntable.

Using a turntable for a run-round release is not so common, but there are quite a few. The best known one is Bembridge on the Isle of Wight (it's not a sector plate, as this page calls it):

https://sremg.org.uk/location/iow/bembridge.shtml

A very strange arrangement at Allendale, which cries out to be modelled:

https://85a.uk/templot/club/index.php?threads/turntable-run-round.505/

p.s. Harbourne is in that topic too.

cheers,

Martin.

 

[Martin Wynne]

.
p.s. Here's one at Rothbury:

https://flic.kr/p/Yrh41K

Martin.

 

[Phil G]

Hi Martin,
well I would never have though about looking though old Templot posts to find that sort of information.

Looks like I should take more time and revisit the disused stations site. To be very honest I got quite disappointed when I found they have not covered Heaton Norris station on there site.
By the way does anybody know if the site is still active?
cheers
Phil

 

[Phil G]

p.s. Here's one at Rothbury:

That one is almost double slip replacement, type turntable.
cheers
Phil,

 

[Phil O]

The much modelled Ventnor Station on the I.O.W also had a turntable for loco release.

 

[Terry Downes]

Hi everyone,
I've been a bit absent recently. I've had my head down laying some track and trying to ascertain what the difficulties might be in laying laser cut plug track in a layout setting.
I've been working on my S4 challenge project, working with just the baseboard tops to begin with. I'm sure there are those who will say I should have built the complete baseboards before laying track, but there are several reasons for progressing this particular way, more of which later, but for now I thought I'd share my progress.
I must stress that at this stage, I am just testing out some ideas, and I'm happy to take all of this up and start again if need be, but so far so good. Stock all runs well (as far as I can test at this stage).

I found the assembly process really enjoyable, the major plus being being able to temporarily fit track to ensure alignment between timbering bases before gluing down, and also across baseboard joints. Everything I have laid here is removable, so very easy to go back and replace parts as required.
I've found that filing down some short lengths (40mm) of rail such that they fit into a chair socket useful. The help to hold a long rail length in place whilst chairing, especially on a curve. Other than that everything else has been pretty much to Martin's words and music.

View attachment 8753
View attachment 8756
There is still some fettling to do, but I hope this provides some inspiration for others to try.
Given that this layout will be exhibited (I hope), I've been experimenting with different methods to ensure reliability and hopefully eliminate damage to sensitive areas such as the common crossings and check rails etc. To that end I've played-around with various bits of nickel silver bonding strips, and brass pins soldered under the check rails to restrict movement. They look a bit crude at this stage, but everything is rock-solid. I've found that I can grind the protrusions away quite nicely so they should be pretty inconspicuous when complete. Of course, had I used FDM timbering then I would have incorporated Martin's neat little solution of the restraint wires.
I've packed it all away now as I've had enough of track for this weekend, but next time I'll get some more detailed photos.

I've also built the well for a 50' Cowan's turntable, and used plug track chairs for the race rail.
View attachment 8754
The TT well and its motor are quick-release, being held by thumbscrews.
View attachment 8755

All looks great James. I'm running slightly behind You and getting similar results which I will post soonish hopefully. I Just wanted to pick up on the 'sensitive areas' e.g board joints etc. I have been considering this area lately and I was thinking about purchasing some of the C&L brass chairs or DCC concept brass chairs soldered onto timber cladding. Has anyone explored this before?

 

[KHC1]

Well done James that all looks great. I am waiting for better weather to set up the resin printer. Also had a slight delay as my Wife was taken ill and it’s knocked things back a bit(had to learn to use the washing machine!). As always looking forward to your next video…….

Keith

 

[James Walters]

A little bit of progress yesterday, and I've managed to get the bare bones of my S4 challenge baseboards put together. Still clearly much to do, but I will now be able to fit the tops, and finesse my earlier Plug Track work. I want to get this wired-up and operable in the near future to thoroughly test as I've been invited to demo again at Scaleforum and it would be great to have some functioning Plug Track for folks to have a look at and play trains on.

Here's where I've got to:

There's been some progress with other elements as well, such as the wagon hoist. Here it is, complete with 3d printed stainless steel lift frame and a suitable 3d printed wagon with springing. Apologies for the terrible soldering of the hand-rail. I literally knocked this up in 5 minutes before setting off to a S4 area group meeting having left my spectacles in the car. I hadn't anticipated putting a high-res photo on the internet so please squint when you look at the photo.

Whilst I'm at it, here's the first carriage off of the production line, still needs some fettling of the .stl to produce a clean print, but it's not bad. It's a 2 piece print and fully sprung.

James

 

[Martin Wynne]

@James Walters

That looks smashing James. Great progress.

I like the 2-colour chairs! Is that paint, or are you trying coloured resin? I have some of this, but I haven't tried it yet:

https://www.3djake.uk/3djake/resin-colorant-brown-beige

cheers,

Martin.

 

[James Walters]

Thanks Martin,
It's paint. I'd airbrushed a quantity of chairs and loose outer jaws, but not all of them and got carried-away putting it all together. I'll get them all painted in time.
That colourant looks great, I didn't know they made it. I shall have to try some out myself.

 

[KHC1]

That looks fantastic and for me heaven a Landrover and a layout. Just as a matter of interest you say you painted your chairs and loose jaws. Did this present any problems? When I suggested it sometime ago Martin sounded a note of caution. I am currently exporting chairs and timber Base files. For chairs I am doing both full and loose jaws versions. My thinking is using one or two full chairs to hold track in position and then use the loose jaws.

Keith

 

[LassUnsSchaun]

... S4 challenge ... I've been invited to demo again at Scaleforum and it would be great to have some functioning Plug Track for folks to have a look at and play trains on.

I'm not sure about the challenge rules, but isn't it that you are not allowed to exhibit before S4 challenge show in which it contests?
little correction; "play" -> "realistically operate"

View attachment 9458

*looks at the production surface structure of the I-beams instead* please correct the pattern direction with fine abrasive paperand and add some riveting

Whilst I'm at it, here's the first carriage off of the production line, still needs some fettling of the .stl to produce a clean print, but it's not bad. It's a 2 piece print and fully sprung.


View attachment 9459

James

*reads "fully sprung", expectes something like this

and waits expectant, as well as patient, for demonstration*

LassUnsSchaun

 

[KHC1]

I believe in one of his videos James has said he is not entering the competition. However he is using the competition rules to build a small layout as a demonstration piece.

Keith

 

[James Walters]

That looks fantastic and for me heaven a Landrover and a layout. Just as a matter of interest you say you painted your chairs and loose jaws. Did this present any p

That looks fantastic and for me heaven a Landrover and a layout. Just as a matter of interest you say you painted your chairs and loose jaws. Did this present any problems? When I suggested it sometime ago Martin sounded a note of caution. I am currently exporting chairs and timber Base files. For chairs I am doing both full and loose jaws versions. My thinking is using one or two full chairs to hold track in position and then use the loose jaws.

Keith

Hi Keith,
The Landrover is my pride and joy, I could wax lyrical about how marvellous it is all day long. Few would agree though.
When I painted my chairs I gave them a very light squirt with the airbrush. I did my best to avoid the pins on the loose jaws and by spraying horizontally to the chairs managed to avoid the slots. I haven't had any problems - but I was mindful of the risks at the time and so was cautious. They will all get painted again later once everything is fully fastened down.

Cheers,

James

 

[Martin Wynne]

Hi Keith,
The Landrover is my pride and joy, I could wax lyrical about how marvellous it is all day long. Few would agree though.
When I painted my chairs I gave them a very light squirt with the airbrush. I did my best to avoid the pins on the loose jaws and by spraying horizontally to the chairs managed to avoid the slots. I haven't had any problems - but I was mindful of the risks at the time and so was cautious. They will all get painted again later once everything is fully fastened down.

Cheers,

James

And a drift from an airbrush is not the same thing as a scoosh of red oxide primer from a rattle can.

Martin.

 

[James Walters]

I believe in one of his videos James has said he is not entering the competition. However he is using the competition rules to build a small layout as a demonstration piece

I've entered the competition, but I'm not at all fussed for the competitive element. I know who some of the other entrants are and frankly I'm not in their league. I am interested in building something though simply for fun, according to the Gospel of Plug Track, to demonstrate what is possible. However, I can foresee the Scalefour devout becoming offended with REA chairs on a c.1900 Midland Railway layout.

My pals in my local area group know my intentions to build a 'train set', and seem quite happy to cheerfully agree to it being a good wheeze, and that's good enough for me.

I will only take one of the baseboards to Scaleforum, and it will of course be unfinished so I doubt there will be any cause for disqualification - but who knows? Personally, I'd consider it a win if my efforts helped others to become excited about the possibilities of Plug Track.

Anyway, here's (roughly) what it should/might look like:

It looks like a fish from the top.
James

 

[Martin Wynne]

Personally, I'd consider it a win if my efforts helped others to become excited about the possibilities of Plug Track.

@James Walters

Not too excited I hope! There's still a long way to go, and I'm trying to manage expectations.

However, I have now posted open-source all the code which generates the chairs, so maybe someone will pop up with the code for some GWR chairs, or the bridge check rail chairs say, or whatever. Maybe ChatGPT would do it, if we asked nicely?

The layout design is looking excellent James.

cheers,

Martin.

 

[LassUnsSchaun]

I've entered the competition, but I'm not at all fussed for the competitive element. I know who some of the other entrants are and frankly I'm not in their league. I am interested in building something though simply for fun, according to the Gospel of Plug Track, to demonstrate what is possible.

Relative, very relative.

Yes, there might be some that are known to be better, but life could come between for those or their layout happends to get dimensional to big on the way.
And then there should be some unknown, that enter to give it a try.

Your plan got alot in it in relation to the space.

However, I can foresee the Scalefour devout becoming offended with REA chairs on a c.1900 Midland Railway layout.

How about not telling them about this detail?

My pals in my local area group know my intentions to build a 'train set', and seem quite happy to cheerfully agree to it being a good wheeze, and that's good enough for me.

train set = classical oval made out of bought (fix length and radi) track on the floor or with landscape on a board

I will only take one of the baseboards to Scaleforum, and it will of course be unfinished so I doubt there will be any cause for disqualification - but who knows?

They got a forum and topic to ask (and, as fare I looked it up some time ago, they want to follow the build themselves).

Personally, I'd consider it a win if my efforts helped others to become excited about the possibilities of Plug Track.

A bigger win, when such a layout is in a competion for comparison with others

Anyway, here's (roughly) what it should/might look like: ...
... It looks like a fish from the top.

Looks like someone wants to win in the categories "layout design", "complexity of track" and "clearly not simple to operate all possible movements"

LassUnsSchaun

 

[James Walters]

@James Walters

Not too excited I hope! There's still a long way to go, and I'm trying to manage expectations.

However, I have now posted open-source all the code which generates the chairs, so maybe someone will pop up with the code for some GWR chairs, or the bridge check rail chairs say, or whatever. Maybe ChatGPT would do it, if we asked nicely?

The layout design is looking excellent James.

cheers,

Martin.

I've not looked at the code yet, and I think I wouldn't understand it if I did. That said, I'd be very happy to help with chair drafting, maybe I could create some 3d models for ChatGPT to work from. I've no idea how that all works but very interested to follow the developments.

Thanks for the kind comment about the layout design, it's presently on it's 29th iteration and quite removed from where I started.

 

[James Walters]

Relative, very relative.

Yes, there might be some that are known to be better, but life could come between for those or their layout happends to get dimensional to big on the way.
And then there should be some unknown, that enter to give it a try.

Your plan got alot in it in relation to the space.


How about not telling them about this detail?


train set = classical oval made out of bought (fix length and radi) track on the floor or with landscape on a board


They got a forum and topic to ask (and, as fare I looked it up some time ago, they want to follow the build themselves).


A bigger win, when such a layout is in a competion for comparison with others


Looks like someone wants to win in the categories "layout design", "complexity of track" and "clearly not simple to operate all possible movements"

LassUnsSchaun

I'm quietly rooting for another's entry contest-wise, as it's bound to be beautiful, but I shall keep the identity under my hat for fear of being accused of favouritism.
I was being a little cheeky by suggesting folks might take offence at the REA chairs. Certainly all the society members I know will be thrilled to see another layout on the circuit - as long (of course) as it works. So that's the main priority for me.
Hopefully I'll have something running in the next few weeks.
Best wishes,
James

 

[Steve_Cornford]

ps it's a challenge not a competition

 

[James Walters]

Exactly.

 

[Michael Woods]

James - I am late to this thread but this is very impressive!

 

[Phil G]

Hi James,
I have been a bit absent since mid March so only just caught up with this post, I have to say just like everybody else your making fantastic progress.
Just a question about the MR 5 plank, which I presume you have 3D printed yourself, which also looks fantastic, amazing detail on the wagon, especially the wagon number on the soleplate and the MR on the Ellis axle box what depth did you use? Prototypically from what I have been able to gather they were somewhere between 0.4 and 0.5 inches thick which would be about 0.005 and 0.0065 thou respectively but thats for the full plate thickness with the raised numbers being only half that. I presume your slightly over scale to get such a good looking number plates?.
Also re suspension I am currently working on some RCH wagons and I am thinking of a resin version of the Bill Bedford style of spring wire suspension should work, as Bill in fact now sells some of his resin wagon kits complete with suspension which I presume is a resin version very similar/same as the etch brass version. This system was so good before it became so hard to get hold of. I have even considered just leaving a slot in the sole bar to take an etch brass suspension system. Just wondering which way your thinking of jumping. or have jumped.
And most importantly how does such a wagon run on plug track?
cheers
Phil,