The Dixie Central Railroad in HO: Building a Turnout

Monday, February 1, 2010

Building a Turnout

It appears that I might need to scratchbuild a turnout for the pier area. Really it needs a little bit of a curve to it to work.

I pulled a #5 turnout template off of Fastracks...

http://www.handlaidtrack.com/ho-5-turnout-printable-track-template-free-download-pi-2223.php

So we'll print it and get started.

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Layout Parameters

Name: The Dixie Central Railroad
Scale: HO 1:87
Gauge: Standard 4' 8 1/2"
Dimensions: 8' x 8' circular with 3' diameter center pit, 40" high to base, 43 sq ft layout top
Prototype: Freelanced, based on Southern
Theme: 1940's cotton and textile hauling
Railroad's Purpose: Move cotton from the fields through finished textile stages
Layout Purpose: Skill building in the areas of scenery and construction. Modular concept that allows layout to be movable for train shows and for teaching purposes.
Location: East Georgia
Era: 1940's
Style: Twice around, pit design
Mainline Run: 33' long main line
Min Radius: 22" min radius
Min Turnout: #5
Ruling Grade: 2.8%
Track Saturation: tbd
Design Parameters: Portable, one man set up, lightweight, durable. Minimize hidden track, two track joints per module side. Minimize tangent track, lightweight (portable) construction techniques.
Benchwork: Lightweight waffle style based on Sipping and Switching Society modules. Foam scenery base
Scenery: four seasons represented, each module being a different season
Control: Digitrax DCC or equivalent
Operation: one man, center pit control for home use. Two train, 5 operators for show or open space operating. Car card and waybill for movement. TT/TO for trains.
Track: Walthers code 83, all turnouts manual throw for realism and more complex operations.
Other: Waterways removable for "off layout construction", modular scenery system

Materials Used in Construction

Luan Plywood - 4x8 sheets (5) $8.94 each - $47.82
Drawing Print Out on Plotter (1) - $22.25 (refunded)
Table Leg Sets (2) - $44.97
Steam Locomotive w/DCC & Sound (1) - $262.00
CofG Box Car (1) - $13.00
Masonite 2'x4' sheet (1) - $5.06
Corner Round Trim 6 feet (1) - $3.84
Box 1 1/4" drywall screws (1) - $4.00
Wood Glue Tight Bond (1) - $2.78
Liquid Nails Heavy Duty (1) - $2.26
Structures and cars from Steve (9) - $50.00
Boxcar Seaboard - $29.67
Palm Sander (1) - $29.97
Glue (2) - $5.84
Table Leg Sets (2) - $47
Pipe, caps, threaded rod, nuts, washers - $9.92
1 1/4" drywall screws - $2
2" drywall screws - $3
Pipe, caps, feet for legs - $10.63
Extruded foam insul 4'x8'x2" (4) - $113.42
ME Track code 83 weathered 3' (12) - $64.50
Boxcar - Used Seaboard 19555 (1) - $4.47
Hopper - Southern 2 bay #104500 (1) -$24.00
Walthers Code 83 #5 LH Turnout (1) - $21.25
Walthers Code 83 #6.5 Curved LH Turnout (1)-$32.08
Two Bay GM&O WE Hopper (1) - $5.29
Sanding belts (2) - $8.54
2'x4' Hardboard Sand Ply - (2) - $17.46
2'x4' Masonite 1/8" - (1) $4.40
HO cork roadbed case (1) - $25.95
Digitrax Super Empire Builder Set (1) $274.95
1/4" 4x8 Sandply Plywood (1) - $18.99
1/8" 4x8 Masonite (1) - $6.75
Aerosol paint flat black (1) - $2.99
L&N Drop End Gondola (1) - $11.34
Southern Drop End Gondola (1) - $10.53
Car Weights Pack (2) - $9.00
1/8"x1/8" Basswood for pier (11) - $9.21
1/8" dowels for pier (25) - $9.10
Boxcar Southern 27257 (1) $8.00
Flat Southern 116056 (1) $8.00
Flat L&N 24239 (1) $8.00
Tank GATX MA 32316 (1) $8.00
Tank GATX 16101 (1) $8.00
Misc small structures (5) - $20.00
Pier Lumber bundle (1) - $12.50
Boxcar GA Railroad (1) - $8.00
Caboose Southern (1) - $8.00
Boxcar Cotton Belt (1) - $6.00
Kadee 33" Wheels (12) - $7.25

---------------------------------------------------
Project Total $1,353.23
Budget $1,500

Construction Time

Layout Design - 8 hours
Operation Plan - 1 hour
Shopping for Lumber - 1.5 hours
Construction Bases - 3 hours
Construction Bases and Sec #1 - 3 hours
Base Inner Radius - .5 hours
Operations Design - 2 hours
Complete Section One - 1 hour
Trackwork Study - 1 hour
Build Section 2,3,4 - 2.5 hours
Build Section 2,3,4 - 3 hours
Saw Sections - 1 hour
12-13-09 Section 3 - 30 mins
Shopping and structures - 1.5 hours
Complete sections (Done!) - 1 hour
Remove clamps and check - 30 mins
12-20-09 Purchase leg material - 40 mins
12-20-09 Leg assembly S1 - 1 hour
12-20-09 Research - 1 hour
12-21-09 Leg final assmbly - 2 hours
12-22-09 Buy foam sheets - 1 hour
12-23-09 Visit hobby shop - 1 hour
12-24-09 Visit hobby shop - 1 hour
12-25-09 Clean up shop - 2 hours
12-27-09 Trip to hobby shop 1 hour
12-27-09 Elevation Corrections on drawing - 1 hour
12-27-09 Sanding section 3 - 45 minutes
12-29-09 Sanding completed - 2 hours
12-30-09 Assemble and foam Section 3 - 4 hours
12-31-09 Clean up shop and organize 4 hours
01-01-10 Trip to Home Depot & work 1 hour
01-02-10 Foam cutting and draw track cl - 3 hours
01-08-10 Pier construction -1.5 hours
01-09-10 Pier drawings - 1 hour
01-10-10 Pier assembly - 5 hours
01-11-10 Pier assm, rolling stock work - 3 hours
01-13-10 Foam cutting - 1.5 hours
01-16-10 Working on Pier - 4 hours
01-17-10 Working on Pier - 5 hours
01-19-08 Working on Pier - 1.5 hours
01-20-10 Working on Pier - 1 hour
01-21-10 Working on Pier - 1 hour
01-22-10 Working on Pier - 30 minutes
01-23-10 Working on Pier - 2 hours
01-24-10 Working on Pier - 3 hours
01-29-10 Working on Pier - 2 hours
01-30-10 Benchwork & Rolling Stock - 3 hours
02-07-10 Benchwork Sec 4 - 2 hours
-----------------------------------------------------------------
Total Hours: 92 hours

* Blog time is NOT included but taking and processing photos is included.

Tools Used

Sabre (Jig) Saw
Sanding Sponges
Measuring Tape
Pen - Gel Marker
Speed Square
Extension Cord Heavy Duty
Table Saw (use high quality!)
Screw Gun/Drill
Countersink Bit
C-Clamps (8) 6" opening
Digital Camera
Chop (Miter) Saw
3 x 8 Work Table
Hand saw
Safety glasses
Table Saw Push Stick
Caulking Gun
Gap Gauge (hand made)
Bar Clamps ( I didn't have any but they would have been handy on the radius installation)
Palm Sander - Electric
Belt Sander
Large Rasp for Foam
Radius Drawing Tool (I don't have)
48" metal rule
36" metal rule
48" drywall square
16" metal rule
24" metal square rule
Rolling tool tray
Radius Tool (for turntable)
Serrated edge knife
Spackling Blade 6" (Cutting foam)
Pliers
Utility knife and blades
Hobby Knife
Old saw blade
Plastic tray
Metal condiment cup
#8 Paint Brush
Small clamps (6)
Popsicle Sticks
Northwest Shortline Chopper
Chop Saw - Harbor Freight
Scale People in HO - Measuring
Curved Tip Tweezers (Sharp)
Round Toothpicks

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