New header for our modules' standard

Happy New Year everybody!!! This is my first post of 2017

We are ready to publish the revision 3 of our modular norms. Remember in the top horizontal menu, under "Modules" option, you will find always all the posts and the last version of the norms once approved.

A big change in this new version refers to the header construction and shape. Our adopted header was the same from the EuroN norm:

EuroN header (ClubNCaldes v.1)

Everybody told us that the squared hole (the one on the right side) was never used. In the original EuroN norms that hole is to pass two hidden tracks to cross under the modules. But if even having the tracks in sight sometimes is difficult to adjust them, having them hidden looks like it can cause many headaches and train derailments in a zone that you cannot see and has difficult accessibility. So we decided to get rid of it and center and enlarge the existing rounded hole that we use to pass the wires and connect one module to the other, and as a handle to move the module.

At the same time one of the club members had the idea to make a reversible module, so you can flip it and interchange North and South sides with no problems. Another friend wanted to make a staging yard of 6 tracks, but having a kind of norm or guide for it and to place the tracks. In this way any staging yard module (with 6 tracks) can be joined to the one from any other club member as everything has been constructed under the same norm.

These are the reasons to design a new header, fully compatible with EuroN and our previous header norm, but having the holes to place the metallic gauge in three different positions. The two outside positions allow to place 4 tracks so that the module is symmetric and North and Sound sides are interchangeable. A center position of the gauge allows to place two extra tracks centered in the module.

ClubNCaldes header v.3 (compatible EuroN)

I will upload the last norm version soon, as it contains more detailed information and step-by-step instructions to build the different Loconet modules using Arduino.

Two steps ahead, one back

It's been a long time since last time I showed my layout progress, but once you start with electronics, DCC, software programming and all electrical stuff you cannot see any real advance on the surface. Just one or two more switches and some centimeters more of track.

But down the layout it was crowded of electronic boards and temporary wires. So crowded, that I decided to dismount everything and think in better solution because I was running out of space, and illumination and future sound are still missing.

Sometimes you have to make a step back to be able to continue advancing with a bit more of security...

That's why I planned to create an hydraulic hatch down the most overcrowded part of the layout: the main station. There I have concentrated the major part of current sensors, servo driving modules, frog polarization relay boards.... and working upside down is too stressing!!!!

Here you can see the whole hatch and the hydraulic pistons that support it and open it in a very smooth way and with a cool sound effect, just missing some fog effects!!!! xDDD

 

Just some details about boards: on the bottom the Loconet interface (using DB9 connectors instead of RJ12), and on the top (left to right) the detection module and a sandwich board with servo controller and frog feeding relays:

 

 There are still many temporary wires, because I like to test everything step by step, or you can get crazy if some error appears when everything is connected.

Before the hatch, all boards where attached to the sides of the ribs: 

I hope to post soon the final results!!

Preparing main level

All the hidden tracks have been laid and tested, so it's time to cover them and loose the comfort that gives you the possibility to work with the frame opened.

I tried to find a way to do it to be able to dismount it in case of "emergency". And the only possibility was to screw the base instead of gluing it. And it's been a good idea because it's faster and stronger. There is also the advantage to be able to level it. For sure it will not be easy to dismount if some day it's needed, but at least there is the possibility without breaking a lot of things.

The first thing to do is to be far-sighted and lower some notches on the top of the ribs for passing wires. Make a big hole if you preview access from the side can be needed (big enough for your hand at least). It's still difficult to know how many wires and where will they go through, so my recommendation is to drill four notches in each rib crossing like in the image:

In order to fix the base board I used metallic squares screwed to the ribs. In the base board I drilled a hole for each square and countersink it. The inox screws I'm using have conical head so once in the hole they are leveled.

These are the tools and material used:

Level 0 planning

Just a short update, now I'm planning the main level. All the hidden tracks are in place and wiring ready (DCC loop, feeder connectors for all tracks and Loconet Bus).
What you see is the rural station from Kato with the platform extension pack:

I'm still waiting to receive some latching relays with double coil to manage the loop. The layout is basically a dog-bone, and the concrete sleepers track (on the right of the photo, lower level) is one of the ends of this dog-bone that must invert the polarity when any train crosses it. After I have that I'll post a video recording the available run.

Structure completed!!!!

After an insane work, I completed the whole structure. Still remains the third module, but it's just for the future because now I have enough work to complete this 2,60x1mt model ;)

I had some trouble because plans were printed something like a 5% bigger than 1:1 scale. I haven't found the error, something wrong with the printer I guess, but the following ribs' plans were printed in the right size (and that's the really important thing!).

I also prepared the base for the hidden stage yard and I've start laying tracks and connecting. I'm doing some tests with Uhlenbrock feedback modules, Intellibox and Rocrail. I'm getting really satisfied with it by the moment... In later posts I'll show how I'm planning the electrification.

These are the materials and technique used:

* Ribs and frame: Phenolic plywood 1 cm.
* Track bed: Phenolic plywood 0,5 cm.
* Legs: 6x6 cm pine strips

Frame and ribs where fixed with cyanoacrylate glue (bought from Würth here) and the intersection between ribs with a special water resistant white glue for wood (E+D3 glue). This kit has an spray to activate the cyanoacrylate and fix it IMMEDIATELY!!! I'm not kidding, it glues immediately with your fingers, your shirt, tools, everything in contact will be fixed. So I suggest to buy the full kit or you will miss the cyanocrylate remover.... Don't put cyanoacrylate in one side and the activator in the other or as soon the two pieces get in touch it will not be possible to separate. Put cyanoacrylate just in one, joint the pieces (you have 5 minutes to adjust) and once they are well situated, slightly spray the joint. I also screwed the union between ribs and external frame. And again I suggest you to use the Würth "ASSY PLUS" screws with a special drilling end that will not break the wood and you don't need to drill before screw, and half thread to push one piece to the other instead of separate them as it happens with normal screws.

Inicio de la infraestrctura (2)

Aprovechando las vacaciones, he podido armar la infraestructura de media maqueta. Todavía no la he encolado porque faltan algunos retoques y un poco de lija en algún punto, !!!pero parece que el Wintrack funciona a la perfección!!!

Lo próximo es fijar todas las maderas con cianocrilato y algún tornillo, pero antes prefiero esperar a tener también la cama de las vías para comprobar que todo encaje. Me parece demasiado raro que todo cuadre tan bien a la primera.... :S

Inicio de la Infraestructura

!Fase de construcción iniciada! Después de un año haciendo y rehaciendo planos y bocetos, y habiendo dibujado mas de 18 variantes distintas de la versión mas o menos final de la maqueta, estoy construyendo por fin la infraestructura.

En primer lugar quiero agradecer a los foreros de Plataforma N y de JNS Forum por el montón de consejos que me han dado y el cariño y paciencia con los que se han mirado mis planos y los han corregido o aportado sugerencias.
First of all I would like to sincerely thank to all the collegues from Plataforma N and JNS Forum for the big ammount of advices given and the patience and affection demostrated when looking at my plans and correcting them or giving suggestions.

Siguiendo los consejos de los mas experimentados tanto en maquetas como trabajando la madera (gràcies Edu!!!), estoy utilizando madera contrachapada fenólica de Okume de un centímetro de espesor, tanto para el marco como las costillas. La base de las vías es también contrachapado fenólico de Okume de 5 mm.
De momento he calculado las costillas justas, cada 32.5 cm exactamente, y ya reforzaré si lo veo necesario con alguna costilla mas o algún tirante o escuadra.

La maqueta la construyo en tres trozos, para que sea mas o menos sencilla de transportar en un futuro. Los 2 primeros trozos que construyo miden 131 cm x 102 cm. He utilizado el Wintrack 8.0 para hacer los planos e imprimir las plantillas de las costillas a tamaño real.

Seguiré posteando los avances.