Milestone reached in layout construction, I put down the first lengths of flex track last night. All the benchwork for the round-the-walls layout is up. Made the shelf brackets, the plywood tables, found the studs, sank the drywall screws thru the brackets into studs. Shelves made up from 1/2" plywood and 1*4 lumber, glued, sanded, painted to match the room. A layer of 2 inch blue foam cut to fit the shelves, beveled, and stuck down with latex caulk. Came out level, all way round the room, and doesn't sag anywhere. Awesome.
I wanted roadbed that would take track nails, and that means wood. Plywood is too hard, the glue layers will bend the track nails. Cork is too soft, the track nails pull out.
To get 1/4" wood for the roadbed, the newly acquired Craigslist bandsaw was able to resaw ordinary 3/4 inch pine into 1/4 inch slabs. Used a sharp blade, widest the machine will accept (1/2" for my saw). Made a fence from 3/4" plywood and c-clamped it to the bandsaw table. Feed slowly. A new blade will cut straight without drift. Straight and standard curves are simple to cut. For the fancier trackwork, easements on curves, turnouts and such, lay out the track full scale on poster board. Then cut the track shape out with sissors and use as a template.
Once cut, bevel the edges with a router, mounted in a table. Made my router table up from scrap plywood and except for amplifying the scream of the router, works well. Stick the newly made roadbed down with PL300 Foamboard adhesive. $2.99 a tube at the hardware store, and it says "Foamboard compatible" right on the tube. You get 10-15 minutes of working time, and then it needs over night to harden. Weighted the roadbed down with the usual assortment of heavy objects from the shop Paint cans, tool boxes, vise, etc.
Once dry, a sharp plane will level the joints between the pieces of road bed. I decided against using the belt sander 'cause it cuts awful fast, and throws sawdust everywhere.
Started laying track at the turnouts. Used 1/2" twist drill to bore a hole for the under table switch machine (Tortoise) operating rod. The twist drill makes a clean hole thru the pine road bed, the foam subroadbed and the plywood foam backing. I don't recommend a spade bit for this trick. Since the turnouts need to be accurately centered over the operating rod hole, nail them down first and cut the rest of the track to fit. Pine roadbed loves track nails, I can push them in with long nose pliers and they stay down.
At this rate, I might be able to run a train in a week or so.
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