Page 10 - May June 2012

A second look at modules: Part 2, BenchworkTom Winlow
This article is the second of a series covering the construction of a module to the Region’s new HO specification. Last time we looked at some of the recent developments in modular rail- roading. This month we’ll start the construction by building the benchwork for our simple rectangular module. This is made up of two boards, each 36 inches × 18 inches. However, as explained last time, the new module specification allows lots of freedom in module shape, so if you plan something more ambitious, please see the specification. This is in the members’ area of the British Region’s website (www.nmrabr. org.uk).
I usually prefer lightweight boards, but in this case lightness has been sacrificed for ease of construction. It is hoped that this simple approach will encourage you to build a module (or two) of your own. The design of the board is based on that of Chris Green of Seaboard Southern. If you don’t feel confident about tackling woodwork, Chris is prepared to supply a very limited number of boards to this basic design. Contact details are in the Directory. You will need to arrange collection from Chris though. There are also professional baseboard suppliers who advertise in the model press and can supply boards to various designs.
This article goes into quite a lot of detail and is really intended for people who aren’t familiar with board construction. I have no carpentry training beyond what I have picked up from various DIY and railroad activities. If you are more experienced, and have a favourite construction method, please use that. The new specification is non-prescriptive on construction methods, so long as your design meets the dimension requirements. Photo 1 below shows one of the boards. The second one is almost identical. They fit together to form a module 6 feet long. The small pale circles are patches of filler coving the screw heads.
In this article we will cover the construction of one of the boards, followed by the leg assemblies.
Photo 1: Complete single board
Incidentally, the colour of that wall doesn’t reflect the Winlow domestic colour scheme! The photo was taken at a Bearwood meet.
Basic components
Fig 1 shows the main components and how they make up a simple plywood box.
It is good to have all the plywood cut by a timber merchant. The professional machines will produce dead-straight cuts that are at right-angles. My local supplier charges 15p per cut, which is an amazing deal, considering the time saved and the quality of the work. Unlike the large DIY chains he is also willing to cut softwood to length, so it is possible to return from the timber merchants armed with a complete module “kit”.
Fig 1: Board Assembly
top: 9 mm ply
914 mm × 457 mm (36" × 18")
Sides: 9 mm ply ends: 18 mm ply 914 mm × 93 mm
Plywood components
439 mm × 93 mm (36" × 35⁄8")
(171⁄4" × 35⁄8")
A batten of 20 mm square softwood is used to join the sides to the top, as illustrated in Fig 2.
Fig 2: Cross section
All screws 1" × #6 (25 mm × 3.5 mm)
Battens
20 mm × 20 mm softwood
Photo 2 shows the underside of one of the boards and you can see the 20 mm square batten. This runs the length of the board and provides an anchor for the screws that hold the top and sides. It also provides a convenient way to clamp the components during assembly.
The small vertical pieces of softwood at the right-hand end of the photo are guides for the legs, which we will come to later.
Photo 2: Underside of board showing batten and leg guides
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