Making the roadbed from GatorfoamI built the module out of 1/2" Gatorboard which I got from foamboardsource.com. It is a truly excellent material to work with - strong and light. I cut it with a utility knife. For straight cuts I use a straightedge to guide a light cut and then cut it fully with a couple more strokes.
I put the pieces together with deck screws and yellow glue. The pieces I used were smaller than my 4' x 6.5' base size so I laminated 2 layers of overlapping pieces held together with glue and 1" screws. The whole thing is light and strong. I can easily pick up and carry the module by myself. Since we put our modules on folding tables, there was no need for legs. If I was to put on legs I think I would use some aluminum channel on the bottom to support them. Also this being a dead-rail module, there is no wiring to put underneath so I didn't make a space for wires.
|The tools I use to assemble the sections of 1/2" gatorfoam together. I bought the gatorfoam in smaller pieces so they could be shipped UPS and saved considerable money.|
|Glue is spread where the sections overlap. I use Titebond II, a yellow wood glue.|
|The overlapping sections are screwed together to hold them while the glue sets.|
|The base is all glued up. I made up the subroadbed which will be raised up over the base with risers by laying it on the base.|
|The plan has been printed out full size on paper sheets. These are carefully trimmed and then taped together. For easier handling I made the plans in to 3 subsections - each town and the connection between.|
|The taped together plan is laid over subroadbed and the smaller sections taped together to make the final plan.|
|With the plan laid over the subroadbed, we are ready to punch holes about every inch with a sharp awl to mark the centerlines and the edges of the subroadbed where we want to cut it away.|
|Ready to lay track. It is hard to see but there are centerlines narked for the track in order to lay it accureately.|
The track has been laid and we are running trains!
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