Category Archives: Human Factors Engineering

Layout Handbrakes for Model Railroads

Layout Handbrake in Action
The St Charles Switcher crew sets the handbrakes to leave a string of loaded hoppers on the grade while working the yard

Gravity is a major factor in prototype railroading, but it can be quite troublesome for a model railroad. Very little real track is actually completely flat, so train crews routinely use the handbrakes on individual cars to hold them in place in yards or sidings. Not only do handbrakes hold cars in place, but in the Appalachians where I model, gravity and handbrakes were often used to move cars from empty tracks to tipple loading points, to move loads into the right track below the tipple, or even to run-around a caboose at the end of the line. Modeling working handbrakes on individual cars isn’t very practical, so what is a model railroader to do? Some install springs on the ends of a car’s axles to use friction to hold the car, but this can’t be “turned off” to allow the car to roll freely. Others use little picks they stick into the ballast to hold cars in place, but this can be destructive to scenery, and it leaves an un-prototypical giant stick next to a cut of cars. I’ve adopted a method of fascia-controlled “handbrakes” on the tracks which works well for my needs.

Layout Handbrake step 1
The first step of the handbrake is to locate where you want the brake, drill a hole, and insert a brass rod sleeve for the brake wire

This method is overkill if you just want to hold cars in place on a siding. For this I recommend a drop of CA, a piece of monofilament line sticking up through the tracks, or the end of a soft brush if more strength is needed–I use all of the above for holding cars in place when set out. I use the method here where I need brakes sometimes and free rolling other times, so the first thing you need to do is figure out where you need brakes. I once heard a story about a design presented to a university for a new campus that didn’t show any sidewalks. When the dean of the university asked the designer why there were no sidewalks, the designer replied “wait a year after the campus is open, then you’ll know exactly where the sidewalks need to go based on the trails through the grass.” So, where do I install brakes? Wherever I find I need them when operating trains–a question I also pose to my operators after every session: “is there anywhere you wished you had handbrakes but didn’t.” Generally speaking, they’re needed anywhere a crew will need to leave cars on a grade for a period of time to conduct other work. Since I’ve got lots of grades on the layout, I’ve currently got five handbrakes installed on the lower level alone.

The concept of these fascia-controlled handbrakes is simple: install a movable piece of strong wire between the rails tall enough to hold an axle with a mechanism to retract it when not in use. Once you know about where you need brakes, mark that spot between the rails, and make sure the area underneath is clear enough to install a brake mechanism. Remember, the brake can really be anywhere along a string of cars, so if your ideal spot is not to ideal under the layout or on the fascia, just move it a few inches. I use 1/16″ brass tube as a protective sleeve for the .025″ steel music wire I use as the brake, so once I find a spot, I drill a vertical hole between the ties for the brass rod. I like to offset the rod about 1/4-1/3 between the rails to avoid interfering with truck bolsters (coupler trip pins will also be an issue for those who use them… in fact, a similar mechanism might work for uncoupling too, hmmm…).

Layout Handbrake Off Position
Here’s the finished control in the “off” position (in line with track)

If you’ve followed me for a while, you know I’m a big fan of manual controls using slide switches–I use them for turnout controls, semaphore controls, and now handbrakes. You also know I’m a stickler for creating a fascia where the controls make sense and aid an operator instead of confusing them. In the case of the handbrake, I wanted it to be easy for operators to see when the brake is “set” and when it is retracted, so I settled on a control lever that lies in-line with the track when retracted and sits at a sharp angle when “set.” Just for good measure, I also use a bi-color LED to illuminate amber on the fascia representation of the affected track when the brake is set to help mitigate inadvertently running into a brake with the delicate footboards of a super-detailed locomotive (been there, done that).

Layout Handbrake Assembly
Here’s the completed brake assembly with three pieces of wood, DPDT slide switch, brake wire (vertical), and control rod (horizontal)

For the brake mechanism, I use a vertically mounted slide switch (DPDT in this case) with a 3/16″ throw–this is just enough to catch the axle of a 36″ wheel in HO scale when extended and still retract to almost rail height when recessed. The brake rod itself is a piece of .025″ music wire bent into a squared-off “J” shape running through a hole in the slide switch–initially, make this piece long enough that it will stick up about 1/2″ or more above the rails when in place. The control mechanism is a piece of thick steel rod (.062″ music wire) with a bell crank bent at one end. Th rod should be cut about 3″ longer than the distance between the brake’s track location and the location of the control on the fascia. The bell crank is offset about 1/4″ from the rod. As you can see in photos, I drill a hole in a piece of 1×3″ board centered on the slide switch and offset about 1/4″ laterally for the control rod to pass through (lined with 3/32″ brass tube for smooth operation). I also bend the bell crank at 45-degree angles instead of 90 as this allows me to make adjustments to the crank offset in either direction, shorter or longer. The structure for the mechanism is typically three boards: 1) the slide switch board with a large hole drilled out for the switch (mounted with screws), 2) the control rod board mounted 90 degrees to the switch where the bell crank is secured, and 3) the attachment board on top to make it easy to mount to the plywood sub-roadbed. I use 1×3″ pine for most of my pieces, but I may use different thicknesses of attachment plates to get the control rod at the right height for the fascia control–the brake wire can be really tall and still work, so better to have the mechanism hanging lower than to have to curve the control rod to the right height. Once I’ve got the three boards assembled with 1 1/4″ drywall screws, I disassemble it, insert the bell crank end of the control rod, insert the bell crank into a hole drilled in the slide switch, adjust the bell crank as needed for smooth operation of the switch, and reattach the boards with the screws.

Layout Handbrake Assembly
The left is the front side of the assembly that will face the fascia–note the brass rod sleeve in the wood where the rod goes through

For the fascia, I drill a hole for the 3/32″ brass rod sleeve as close to horizontal as I can get it and pointed directly at the brake location on the track. I pick the spot on the fascia that allows me to do this while keeping the control rod as perpendicular as possible to the fascia (you don’t want the control rod coming out of the fascia at a strange angle if you can help it). The LEDs are nice but not necessary, but this is the step where I drill the holes, about 1″ behind the brake control. I like to drill the hole through the fascia the exact size of the LED bulb and then use a second larger bit from the back side of the fascia to create a space for the rest of the LED–this keeps the LED from popping out the front of the fascia. I use bi-color red/green LEDs which glow a nice reddish amber when hooked up to AC (e.g., DCC track bus), and I attach one lead to one side of the track bus (with a 470K resistor), the other lead to the “up” position of the slide switch, and a third wire from the center position of the slide switch to the other side of the track bus. Super simple.

Layout Handbrake Under the Table
Here’s the handbrake mechanism installed under the layout–the control assembly should orient to the fascia and not the track

Mounting the switch mechanism is a bit of a pain and requires some planning and patience. From under the layout, I run the control rod through the fascia. Then I find the brass rod going up through the tracks and insert the brake rod (it helps if the brass rod is long enough to protrude beyond the plywood of the sub-roadbed). With the mounting screws on the attachment plate ready to go (screwed in so they’re almost through the board), I gently move the mechanism around until the brake wire is more-or-less vertical, the switch operates freely, and the control rod is as straight as possible between the fascia and mechanism. The mechanism is oriented to put the rod and switch perpendicular to the FASCIA rather than the track (angle relative to track doesn’t matter here). Once I’m happy with the placement, I run the mounting screws into the sub-roadbed.

Layout Handbrake Fascia Control
With the brake in the RECESSED position, bend the control rod parallel to the ground

On the fascia side, I now have about 2″ of control rod sticking out. With the slide switch in the DOWN position, I then grasp the control rod with a pair of needle nose pliers flush with the fascia so the bend will be about 3/16″ from the fascia and use my hand to bend the control rod to align with my track diagram (horizontal) in the direction of the bell crank so that “up” on the control = “up” on the brake. My convention is to face the controls and bell cranks to the left, but either works. At this point, I have the leverage to test the mechanism and fix any issues. If all is good, I use a Dremel cut-off wheel to cut the end of the control rod so about 3/4″ beyond the bend. For the control lever, I use a wooden 1 3/8″ “axle peg” which can be found at any large craft store–it’s admittedly an odd shape, but it’s distinct, easy to find, and easy to use. I insert the pegs into a vice and drill a hole the exact size of the control rod about 1″ deep into the center of the peg, then drill another hole in the side about 1/8″ from the flat end into the first hole and use an X-Acto blade to create a notch between the two for the 90-degree bend in the control rod. The peg is usually a press fit onto the control rod.

Layout Handbrake Wire Height
The brake wire should initially be longer than required in the recessed position

The final step is to trim the brake wire. I’ve found if I use a pair of wire cutters at rail-top level when the brake is in the DOWN (recessed) position, it is low enough for all my locomotives to clear and extends high enough to catch all my axles when needed. Because the wire’s location can be tough to see (especially when cars are over it), I use a little dab of yellow paint on the outside of the rail to indicate where the brake wire lives for easy spotting by crews.

Layout Handbrake Rail Paint
The brake wire can be tough to see with cars on top of it, so I use a little dab of yellow paint on the rail to help operators know the brake location

I’ll also share some “lessons learned” for using this type of handbrake:

  • The brake will find your lowest-clearance locomotive and keep it from moving until you trim the brake wire–remember this locomotive and use it to test all brake installs
  • If you try to pull a string of cars when the brake is engaged, you WILL bowstring every car between the locomotive and the brake off the rails (sometimes violently)
  • If you leave the brake “up” and roll cars into it, they will bounce back quite jarringly upon hitting the brake
  • If you don’t pay attention and activate the brake under a truck bolster or low-hanging part of the car, you WILL raise the car off the rails and derail it (or topple it)

Other than these “gotchas,” I’m very happy with the operational possibilities these handbrakes add to the model railroad!

 

Modeling Paperwork – Moving Trains and Cars on the St Charles Branch

Operations, in my own words, is simply the means by which a railroad – or a layout – moves things to the intended location while keeping trains from colliding over a shared set of rails. Paperwork is an important part of railroading operations, so it stands to reason that paperwork should also be an important part of any operations-oriented layout. No one REALLY loves paperwork, though, so how much is enough? There are as many answers to this question as there are operating layouts, but I’ll share what I’ve settled on because I believe it strikes a pretty reasonable balance and works well for a sleepy coal branch layout like mine.

Paperwork set for the St Charles Local
Everything the St Charles Local needs to operate on the layout

My goals for the layout’s operations:

  • Replicate essential elements of the prototype’s operation
  • Make paperwork realistic without being overwhelming (and avoid tedious paperwork that serves no modelable purpose)
  • Make it easy for operators to work their trains like the prototype and get the cars to the right place with minimal training
  • Avoid creating any boring jobs on the layout (a dispatcher would be a boring job on this layout and thus would always fall to the host)
  • No car cards (I realize I’m tipping some sacred cows here…)

The first step was to understand operations on the prototype St Charles Branch. To help, I had photo captions, excerpts from articles, and some notes from individuals who worked in the area, but the real score was an Employee Timetable (ETT) of the Southern’s Appalachia Division circa 1970. Employee timetables are a critical piece of paperwork on the prototype. They list the scheduled trains for each line, the “class” of each train, the stations they run through, and their scheduled arrival times for each station. In a timetable and train order operations scheme, lower class or unscheduled trains (extras) must keep clear of higher priority trains in the timetable. While the timetable sets the basic scheme of operations, the dispatcher uses train orders for each crew to handle the details, telling them where and when they can work, what trains they need to meet and where, etc.

The Southern’s Appalachia Division dispatcher controlled far more than just the St Charles Branch, so a dedicated dispatcher for my railroad that employs 2-3 operators per session and no more than 2 trains simultaneously would be overkill. In the name of “avoid creating any boring jobs,” I wanted to see if I could completely simulate the role of the dispatcher in keeping the trains moving and separated without actually having a human playing the dispatcher on the layout.

Part 1. Moving the Trains

Employee Timetable

The Appalachia Division timetable listed one Southern second-class train each direction from Andover (the main coal-field yard near Appalachia, VA after 1965) to St Charles daily except Sunday (same crew with a different number for the outbound and return trips) along with one third-class L&N train each direction from L&N Junction to St Charles. All other trains, including the “St Charles Switcher”/”Black Mountain Local” mine runs out of St Charles would run as extras and have to steer clear of the scheduled trains.

Additionally, timetables list all the unique rules and procedures for that division including things like speed limits (20 MPH for the whole St Charles Branch) and instructions for working specific sections of track. One of the interesting sections in the Appalachia Division ETT reads as follows:

“At points shown below, semaphore signals will govern the movement of trains and engines. When track is not occupied, signal will indicate proceed. When in either position, stop or proceed, signal will be fastened and locked with a switch lock. When indicating stop, position will not be changed until train or engine occupying the track clears it and the crew of same restores signal to proceed indication.

  West of St. Charles—located at the junction between Straight Creek and Gin Creek branches.

  West of St. Charles—located at the junction between Bailey Trace and Fawns Branch lines.

  West of St. Charles—located on Black Mountain main near east end track No. 5.”

I had heard about one of these semaphores from a former Southern employee who once worked in the area, but now I knew exactly where they were located and how they were used. This was perfect for my layout because I could use two of the three semaphores to protect long sections of hidden track (e.g., the helix between St Charles and Turners Siding), and best of all, the crews do the work to protect themselves on these lines without the need for a dispatcher or hard-to-model procedures like a fusee or flag.

Clearance Card Example
Clearance card showing how many orders the crew has

Even with these semaphores, trains still used orders giving them clearance to run. Train orders give crews instructions and authorization to occupy certain sections of track and to meet other trains. The dispatcher issues the orders to the conductor and engineer of each train, and the orders can be given over the radio or passed along to the crew by an operator at a station along the way (this was the primary use of semaphores at Southern stations–to tell a crew if they could proceed or needed to slow or stop or pick up orders). I’m no expert on orders, but the two common orders on most railroads are the Form 19 and the Form 31, similar forms in content, but crews needed to stop and sign a Form 31 while a Form 19 could be issued “on the fly.” The Southern seemed fond of the Form 19 while the L&N seemed to use more Form 31s, so I decided to use both. With no dispatcher, I also decided crews would start their jobs by receiving orders telling them their clearances and any other special authorizations or provisions. The practice of picking up orders before moving the train is prototypical, but of course, the train orders were not enough paperwork for the crews by themselves, so the Southern (along with other railroads) required all crews to have a “clearance card” before departing. The clearance card tells the crews how many orders they have and the order numbers for accountability–paperwork, after all, is all about authority and accountability.

So, to get trains working when desired and to keep them from colliding, I would need a timetable, clearance card, train orders, and a couple of semaphores. The actual Appalachia Division Timetable is more than 20 pages long, but I really only needed the sections that 1) apply to the St Charles Branch, and 2) apply to model operations. I’ve created a very condensed, single sheet version of the Appalachia Division ETT which has a cover (having it LOOK like a timetable is important to me), a simplified recreation of the timetable for Andover-St Charles, and instructions such as speed limits, use of semaphores, etc. that would be relevant to a model operator. I used the exact verbiage from the Southern timetable in most places, so it has the “feel” and function of the real thing without requiring an operator to read a 20-page document before running their train. To give it even more authentic feel, I took the time to match the the fonts and formatting as close as possible to the real thing–this took a long time, but I feel it’s well worth the effort. While Microsoft Word or Publisher may seem like the best programs to use, I find it’s far easier to build complex documents in Microsoft PowerPoint where I can control text boxes and shapes better. By taking the time to match the feel of the prototype ETT, the layout’s timetable becomes more than just a source of essential information on schedules and rules; it’s one of many parts designed to transport an operator into the layout’s time, place and purpose. It reminds them they’re working on a piece of the Southern Railway, that their operation is part of a larger “Appalachia Division,” that they’re running a part of a transportation system and not a toy, and their train’s purpose extends beyond the modeled portion of the layout.

Southern Appalachia Division Model Timetable
My one-page recreation of an Employee Timetable for the St Charles Branch

Train Orders

Southern Form 19 Example
An example of my model Southern Form 19 train order

With the timetable in-hand, I now turned to train orders. Because there are very few trains running simultaneously on the St Charles branch, a single set of train orders would likely be sufficient for each train, and because all trains start at a “station” which, in reality, had an operator who could hand orders to the crew, it would be realistic to hand the orders to the crew when picking up the train. To create the train orders, I found images of actual train orders from my era online to use as examples for both the Southern and L&N. Train orders were often given in very simple and standardized language–easy to recreate and easy for a model operator (i.e., non-railroader) to understand. The Southern’s Form 19s were hand-written or printed in bluish ink on semi-transparent green paper, so I use a little color and underlying texture for my rectangle shapes to get this look out of a printer. I found some examples of Southern clearance cards and the L&N Form 31s in a book as well. Like the timetable, I took the time to recreate the Southern and L&N forms as painstakingly as I could in MS PowerPoint. The orders should remind crews they’re working for two different railroads, each with a distinctive culture and personality.

LN Form 31 Example
An example of my model L&N Form 31 train order

As far as what goes on the train orders, I try to keep it simple. The timetable mostly keeps the trains separated, so the most common verbiage is the train’s clearance between points on the railroad and the timeframe that clearance is valid. For inferior trains like the L&N’s CV Local (825/826), I’ll add extra verbiage like a reminder to expect to meet a superior train in St Charles and a reminder to use the semaphores for protection while on the western branch lines. I fully expect this verbiage to be refined as 1) I learn more about the prototype and actual orders used, and 2) I have more operating sessions and see what information the crews actually need to be successful at working and keeping their trains separated.

The scheduled trains on the St Charles Branch are “out and backs” which means they have a single crew and set of locomotives, but they’re technically two trains, one in each direction. This means most crews will have at least two train orders. The L&N crews receive clearance from the L&N dispatcher initially and run according to timetable on the Southern as far as St Charles. From there, they need to pick up a Southern train order to proceed railroad-west past St Charles and work the branches. I’m currently using a clip on the fascia near where the St Charles depot will go with orders to be picked up, and I’ll eventually have a semaphore at the depot I can set to tell the crews to stop.

Train Order awaiting pick-up
A train order awaiting pick-up at St Charles

So far I’ve got a way to keep the trains moving and separated without a dispatcher–time to move on to getting the cars to the right locations.

Part 2. Moving the Cars

There are many ways to move cars on a model railroad including tabs on cars, car cards with waybills, and switch lists. The benefit of tabs on cars is the tab (like a waybill tacked to the car) follows the car and doesn’t create a need to carry a lot of extra paper. It also doesn’t need unique car numbers, something important with model runs of single car numbers a couple decades ago. However, for me, tabs on cars is not an option because I don’t want non-prototypical things cluttering up my models and breaking the illusion of reality more than the models are already doing, and all my cars will have unique numbers anyway. Car cards with waybills do a great job of moving a car’s destination from location to location using the prototypical practice of a “waybill” and providing additional details about a car’s lading. On the downside, they require some training (like when to flip a waybill), they require extra space on the layout/fascia at each town, and they require operators to carry a bunch of cards along with their train–I’ve been at operating sessions where cards went flying, went missing, or got separated from their car leading to messes, “mystery cars” and operator confusion. Additionally, the movement cycles of a coal hopper are very simple, and the lading and load/empty status are self-evident taking away two benefits of car cards.

Switch Lists

SOU-switchlist-blank
Recreated Southern switch list for my layout

That left me with switch lists. Switch lists are used on the prototype, either hand written or computer generated. They’re used mainly on local trains that will be setting off and picking up cars (not really needed for a train that’s not doing any switching). The switch list is specific to a train and tells the crew where each car in their train needs to go using the car’s initials (e.g., “SOU” and “LN”), car number, and some sort of destination designator. They often have additional information such as the car’s tonnage and load/empty status. The switch list is built by the conductor FROM any waybills or other routing information the conductor may have, so a crew doesn’t really need the individual waybills if they have a switch list.

On my last layout, I created a master list of every car on the layout and its destination (call it a “master switch list”), and I provided crews with blank switch lists they could use to build a tailored list for their train, much like a real conductor would do. However, I soon found that only the most die hard members of the crew would take the time to build their own list. For now, I’m building the switch lists for my crews and making it part of their starting paperwork along with the timetable and train order. I use the front side of the switch list for the outbound cars and the backside of the switch list for inbound cars, so crews merely have to flip it over instead of building it. I may revert to having crews build their own (or at least portions of it) in the future, but for now, I view the USE of a switch list as essential paperwork but the BUILDING of a switch list as tedium which I’m willing to endure but not push onto my operators.

To create the switch lists, I built forms in my favorite graphics program (yup, Microsoft PowerPoint) that I print out 3-per-page, front-and-back on thick tan paper and cut out. I found pictures of both Southern and L&N switch lists online (eBay is a great source for pics of old documents like this) and created railroad-specific switch lists for crews (L&N version below).

Destination Codes

A key part of a switch list (and a waybill) is understanding the destination of the car. This can be done in many ways as long as each destination is unambiguous. Because a train usually performs switching within a town/station area, trains are typically “blocked” to group cars for each town/station–this makes it very helpful to include the town/station in the destination for each car. Once the car gets put on the correct train and taken to the correct town, it needs some sort of unique industry identifier, and for industries with more than one track, a unique track identifier. While you can use long-hand like “Mayflower / Mayflower Tipple / Empty track #3” as a destination, it gets a little tedious to write out, so like many other modelers, I use short-hand 2-letter codes for each town and a unique number for every track in the town. Here are my town codes for on-layout destinations:

  • SC – St Charles
  • BK – Baker
  • MY – Mayflower
  • TS – Turners Siding
  • KG – Kemmergem
  • MO – Monarch
  • BE – Benedict

I picked letters that not only make sense for the town name but are also hard to confuse with anything. For example, both “Mayflower” and “Monarch” codes start with an “M,” so I chose a second letter that would be hard to confuse with the other name (i.e., “Y” is found only in Mayflower and “O” only makes sense for Monarch).

Layout Fascia Destination Markings
Track diagram and destination markings on the fascia at Mayflower

For the second part of the designator, I could have gone with a second letter/number for the industry and a third designator for the individual track within the industry. Instead, I opted to only use track designators since it still gets the job done and cuts out an extra symbol. So, for a town that had two industries with 3 tracks each, one industry would have tracks 1-3 and another industry would have tracks 4-6. For tracks with multiple industries on a single track, I use “4B,” “4C” etc. for each destination. For example, at the Mayflower tipple, I have a place to spot boxcars or flatcars bringing in material on part of tipple track 4, so this destination gets it’s own “4B” designator to differentiate it from the tipple. Tipple tracks on the prototype inherently have separate areas for “empties” and “loads”–because an operator can easily see if a hopper/gondola is empty or loaded, I didn’t include this in the destination code. I also created a unique track designator for ALL tracks that could be a destination for a car and not just fixed industries–for example, I sometimes use the end of the main at Mayflower as a place to spot a covered hopper, so I’ve designated the last 12 inches of the main as “track 5.” When looking at a switch list, each car bound for a destination on the layout will have a short-hand 3-letter destination code like “MY3”, or in the case of a track serving multiple spotting locations, “MY4B.”

I don’t expect operators to memorize these track numbers, so I place them on a track diagram on the layout fascia. Each town is clearly marked with its name and its 2-letter destination code. Each track is labeled near the turnout throw with its unique number. Each industry or destination spot is marked by a block at the intended spotting location containing its name and the associated track designator(s). In this way, an operator can arrive at a town, look at the fascia, and by checking the switch list know where each car in the train should go.

Track Chart

Most railroads also publish track charts for all their lines. The track chart contains useful information like grades and curvature, but it also includes a block diagram for each section of track with the town name and a diagram of all the tracks and their length–this diagram is often drawn in a blocky style using only 0, 45 and 90-degree lines. While crews on my layout don’t necessarily need to know grades and curvature, they do need to have a basic understanding of where towns are in relation to one another. For this, I drew up a simple little track chart of the entire layout for operators to use.

Track Chart for St Charles Branch
Simple track chart for my St Charles Branch layout

The track chart is laid out in “right = east” orientation and includes the town names (and short-hand designation) in the correct order. It also has a basic track diagram of each town, and I’ve depicted tipple and depot locations (depots are usually drawn on track charts, tipples are usually not). I’ve also included dashed lines for the hidden areas of the layout with letters that correspond to markings on the fascia to help crews better understand logically where their train is headed when they head out of the visible scene. The track diagram also helps them understand how to construct and block their train when heading west of St. Charles.

Blocking Instructions

Blocking Instructions
Southern Blocking Instructions for layout crews

Speaking of blocking a train, prototype trains aren’t put together in random order but rather are assembled into “blocks” based on the destinations of the cars. Switching and local crews are typically required to block their trains in a certain manner to make them easier to handle at the next station or by the receiving crew, so I want to simulate this on the layout as well. Trains waiting in staging are already blocked by me before an operating session (you’re welcome), so the majority of the blocking for crews is for trains taking cars from the upper layout to staging. I could have just left the blocking at “Southern” and “L&N,” but I wanted to give crews a little more prototypical work to do. In addition to the online destination codes, I’ve got multiple destination codes for the Southern’s offline staging yard representing Appalachia, VA (pre-1965) or Andover, VA (post-1965). The loaders in the vicinity of St Charles loaded mainly two types of coal: raw coal for the huge Westmoreland transloader in Appalachia and clean coal bound directly for customers (routed geographically south of Appalachia/Andover) or to connections east of Appalachia/Andover with the N&W and Clinchfield, so all cars that aren’t L&N have a destination code APP, SOU, N&W or CRR to be used by crews to block their trains prior to returning to staging.

The Southern produced a periodic document called Freight Train Schedules and Blocking Instructions. This book has a page for every scheduled freight on the railroad describing how it should be blocked including engines, cars by destination, and caboose. I’ve created a similar document for my crews. In addition to blocking by destination, I’ve also included blocking instructions that place loaded cars on the head end of empty hopper trains and empty cars on the back end of loaded hopper trains, a common prototype practice to improve train handling on grades and curves. I also add a couple basic instructions for the crew to help them understand the train’s purpose and their chores a little better.

Part 3. Putting It All Together

So, in summary, a crew on the St Charles Branch needs a timetable for basic train schedules and area instructions, a clearance card telling them how many train orders they have, at least one train order giving them clearance and specific instructions for their job that day, a switch list telling them where each car should go, a key for each town labeling destination tracks to match the switch list, blocking instructions to get cars ready for the return trip off the layout, and a track chart to help their brains understand the arrangement of towns and tracks. That sounds like a lot of paperwork, but it really isn’t. First, the “key” for each town is on the layout fascia, so they don’t have to carry it with them. Most of the other bits of paper can be combined into a single sheet. For each train, I build a single sheet that has the clearance card and train orders printed on the left, the train description and blocking instructions on the upper right, and the track chart in the lower right. Now, when you add the timetable and switch list, the operator only needs 3 physical sheets of paper. This is still a bit much to carry loose, so I provide each crew with a clipboard for their train. Clipped on the front is the sheet with clearance card/train order/blocking instructions/track chart. On top of that is the switch list. The timetable goes into a plastic sheet protector on the back for easy reference. Add a pencil and an uncoupling tool (attached by Velcro), hand them a throttle, and they’ve got everything needed to operate successfully on the railroad!

Clearance Train Order and Blocking Sheet
Single sheet for crews with clearance card, train order, blocking instructions, and track chart
Clipboard Timetable
The one-page timetable fits neatly in a plastic pocket on the back of a clipboard

One final note, when using model paperwork, operators need a convenient place to set things down or else they’ll either leave it behind (bad) or set it on top of the layout (more bad). For those who’ve been keeping up with the layout’s progress, you’ll remember the fascia pockets I build around the layout between the staging and lower levels–this is why they exist. No matter where an operator is in the layout room, they’re never more than about an arm’s length away from a clipboard pocket. How about the throttles? When an operator is handling a train solo, they need to be able to quickly set the throttle down to interact with the paperwork. While there are throttle pockets all around the layout, it’s even better if the operator can just keep the throttle with them. This is where the throttle lanyards that allow an operator to just drop the throttle and let it dangle from their neck come in real handy–this is perhaps the best $1.50 solution to a $25.00 problem on the layout so far!

Conclusion

I’ve taken a little more time on this post because I want it to serve as a more thorough article for those looking for ideas on realistic model railroad operations. I will never claim to have “THE solution,” and there are definitely pluses and minuses to my methods. I do believe this method, though, strikes a good balance that gives the die hard prototype enthusiast or ex-railroader enough sufficiently realistic paperwork to make them feel at home while being limited and simple enough to avoid intimidating newbies or weighing crews down with tedious tasks that only a small percentage of people find fun. While I will continue to refine my operations as the layout evolves, this method definitely meets my goals and needs for the short-term. I’m always learning, so please feel free to post your critiques, feedback and better ideas in the comments section! I’ve also included some jpegs of the blank forms below–feel free to use these for your own personal use. The easiest way to “fill them out” is to copy the images into MS PowerPoint or similar program and create a text box on top of the image.

Lanyards for Wireless DCC Throttles

Throttle Lanyard for Digitrax UT4
Wearing a UT4 throttle

I’m continuing to capture little projects on the layout as I think about them. I bought a “spare” Digitrax UT4D utility throttle recently and was reminded of the modification I’ve done to all my UT4s to make them more user friendly. I use the UT4D 2-way radio throttles because they’re light, very easy to use, and the wireless makes them very convenient to use anywhere on the layout. Despite this convenience, there’s still one major problem with the UT4 (or any walk-around throttle for that matter)–where do you set it when you’re not using it? This is not a problem when you’re done with your train as I’ve got plenty of throttle pockets along the fascia in which to stash them and plug them in to keep the batteries from draining. But what do you do with the throttle when you need your hands for other chores like uncoupling and paperwork? This is a major consideration for a switching oriented layout like the St Charles Branch.

On my last layout, I came up with the idea of attaching a simple anchor for a clip-style lanyard. It does require drilling a couple holes into your throttle, but it’s only through a narrow part of the plastic casing and into the battery compartment, so it’s not a threat to the throttle’s electronics. The anchor is made from .025″ steel music wire which you can pick up at most hobby stores. Lanyards come in many styles, but I use the lanyards with the “bulldog clip” that doesn’t swivel and provides a very easy pinch mechanism to attach and release the throttle such as the ones in this link (yes, I get a little commission if you use this link, and it doesn’t cost you anything extra to use this link–thank you).

Here are the rest of the steps:

  1. REMOVE THE 9V BATTERY FROM THE UT4!!!
  2. Cut a piece of .025″ steel wire about 2″ long
  3. Bend into a squared-off “U” with the bottom about 1/2″ wide (just wide enough for the lanyard clip with about 1/32″ of slack) and each side about 3/4″ long
  4. Mark the bottom of the UT4 throttle case for drill holes–make them the width of the U and centered within the “groove” of the plastic
  5. Drill 2 holes into the case–use a drill bit that’s slightly oversized so the wire slides freely without rattling
  6. Insert the wire “U” into the case and attach a lanyard to the bottom of the “U”
  7. Push the “U” into the case as far as it will go and then back off just slightly (“U” extends approximately 1/8″ from bottom of throttle case)
  8. Bend the ends of the “U” that are inside the case outward to mark where the bends need to be
  9. Remove the lanyard, push the “U” as far as it will go into the case and bend the ends inside the case with needle-nosed pliers until they are parallel with the case bottom
  10. Extend the “U” outside the case then reinsert 9V battery, pushing it up against the top (antenna side) of the throttle as far as it will go

You should now have a clip anchor that retracts into the little groove when the throttle is set down on top of it that extends just enough to allow a lanyard to attach when picked up. It doesn’t get in the way of anything if an operator chooses not to use a lanyard, and it provides a secure way to let the throttle dangle when not needed. I’ve been using these mechanisms for years and have never had a catastrophic throttle drop (your results may vary ;-). Similar techniques may work on other throttles as well, though I’ve only tried it on the UT4D.

Southern Whistle Posts on the Fascia

Southern Whistle Posts on the Fascia
A couple of Southern-style whistle posts on the fascia track chart

I thought I’d share a little addition to the fascia–Southern whistle posts. I never thought about this on my last layout because none of my locomotives were sound equipped. Now that I’m moving toward sound, I wanted a way to tell crews when they need to sound the horn for grade crossings. On the prototype, posts are set up on either side of a grade crossing to give the crew enough time to sound off their loooong, loooong, short, looooooooong blast of the whistle or horn. While most railroads used a white sign with a prominent “W” for this purpose, the Southern used a vertically elongated white sign with a stripe, a stripe, a dot, and a stripe (for long, long, short, long). I decided I wanted my posts to be Southern-esque, so I created a simple black-and-white version from basic shapes in MS PowerPoint, sized them to about 1/2″ high, and printed them on a label sheet.

I cut them out and placed them about 15-18″ from the sites of future grade crossings (I have no roads modeled yet) which gives crews about 4-5 seconds of warning at 10 scale MPH, probably about right for the areas where these grade crossings reside. After placing the whistle post stickers on the right side of the track diagram (making them horizontal), I added a little 1/2″ piece of 1/32″ white graphics tape representing the post for the sign to ensure operators can tell which direction the sign is pointing. Once I have scenery, I’ll add some real scale whistle posts trackside, but for now, these will give crews one more prototypical thing to remember while operating their trains.

Building Fascia for Operators

Finished fascia and labels at Mayflower
Finished fascia and labels at Mayflower
Drawing the track diagram
I set a combination square to the right height and slide it along the bottom of the fascia while dragging a pencil across the top to draw straight lines for the track diagram

Working on the fascia is very mundane and unexciting, but as a human factors engineer by education, I take my fascia very seriously! On most layouts, the fascia is the primary interface between operators and the layout. It’s often where we place controls and place names, and it’s also a blank canvas we can use to help our operators better understand the scene they’re interacting with. Like many who perform switching operations on their layouts, I like to use the fascia to help operators understand as much as possible about towns, tracks and industries to aid in making their switching moves.

As far as construction goes, my fascia is just sheet Masonite fastened to the benchwork with drywall screws. I cut it in thick strips that will account for all the vertical scenery contours along the front edge. Where there are noticeable gaps or indentations from the screws, I touch things up with lightweight spackling compound and wipe it smooth with a damp cloth after letting it harden for about an hour–this saves a lot of time sanding later. Then I draw in the ground contour with a pencil and cut it with a jigsaw. A little black paint, and things are ready for the operator features.

Switch controls on the fascia
All the Mayflower switch controls installed–they’re at different elevations to line up with the track diagram that will be installed on the fascia

On my last layout, I drew the track diagram onto the front of the fascia, and it worked so well I decided to continue it on my new layout. It’s essentially an elongated track diagram like you’d find in a railroad track chart that lines up with the adjacent track and switches on the layout. I draw the lines parallel to the bottom of the fascia 3/8″ apart. To draw them, I’ll set a combination square so the end of the ruler is at the exact height I want when the square is pressed against the bottom of the fascia, then I’ll run the combination square around the bottom of the fascia while dragging a pencil along the top to draw it onto the fascia. I draw the switches onto the fascia at 45 degree angles with the convergence drawn where I want the switch control rod to be placed (directly perpendicular to the switch mechanism usually). One lesson learned from my last layout I was able to incorporate into this one is that the “straight” line through a switch control is the “normal” position of the switch while the “divergent” line represents the “thrown” position. It required a little “wiggling” of the track lines in the yard ladder to make this work, but it’s intended to help operators understand how to set the switches before departing a town.

Fascia labels
Finished fascia labels with the town name and siding identifiers for the Mayflower Tipple

I installed the switch control rods (see full article on switch control mechanisms here) after the lines were drawn but before placing the graphic tape on the fascia to represent the tracks. I use two sizes of white graphic tape for the tracks, 3/32″ to represent the main, and 1/32″ to represent sidings. This offers another visual clue for operators so they know which tracks not to block and what to leave clear after leaving town. Next come the labels. Every town on the layout has both a name and a unique 2-letter destination code for routing cars. In this case, Mayflower is represented by “MY.” Within each town, each track has a unique number, for example, MY 1 is the tipple track for the Mayflower Tipple closest to the main. For tipples, I also designate where the empty (MTY) and loaded (LD) cars go, so an empty hopper destined to be loaded on Mayflower’s outermost track would need to be placed at MY 4 MTY. Towns are labeled with large dry transfer lettering with the town name above a line and its destination code in smaller letters below. I also cut a small gap in each track tape on the fascia near the switch and use dry transfer numbers to label each track by number. Industries are given white labels with black lettering that gives the industry name, town initials, track number(s) and MTY | LD track dividing line if needed (see picture of the Mayflower Tipple and its labels). If two or more industries are on the same track, I use a “B,” “C” or so forth to denote each spotting location. In the case of Mayflower, I’ve identified a spot on load track 4 where I might have operators occasionally spot cars of supplies and a spot on the tail track of the main where I might have them spot covered hoppers of AN–each of these spots has its own industry label adjacent to the correct track on the fascia track diagram to make it clear where to spot the cars.

There’s nothing really novel here, but I do think this method of using track diagrams on the fascia and integrating switch controls, town names and industry track designators with unique operational codes goes a long way toward making the layout more intuitive and operator-friendly.

All the Boring Stuff – Wiring, Wiring, Wiring

I haven’t added an update for a while because the layout doesn’t really look any different. That’s not to say I haven’t been working, it’s just been all the boring stuff – wiring. It may be boring, but if you want your layout to run well, it’s doggone important, so it shouldn’t be left as an afterthought.

Power switches for staging tracksFirst, I corrected an issue I first noticed when running trains around the staging level – sound! I never ran sound locomotives on my previous layout, and now that I’ve got a few, I noticed how annoying it is to have diesels sitting in staging making idling noises that are easily heard throughout the room. These trains are supposed to be dozens of miles away, and I don’t want to hear them while they’re in staging. Of course, there’s the option to “mute” a sound locomotive temporarily, but I don’t want to force operators to go through an entire consist muting and unmuting every time they pick up or drop off a train in staging (and every time a short occurred, all the sound would come right back on anyway). For a solution, I went “back to the future.”

I installed a small SPST toggle switch (picked up 20 for cheap on eBay) for each staging or locomotive track (9 total) on the fascia where the track diagram will be. Unfortunately, this meant pulling dozens of feeders from the staging tracks and running a secondary bus for one rail under each track that’s connected to the switch. Thankfully this didn’t involve any de-soldering because all my feeders are connected via wire nuts. Now I can turn off the power to any staging track with sound locomotives until they’re needed, and all the operator has to do is flip a single switch. Old school “electrical block” solution to a DCC problem.

PSX3 InstallationWhile I was at it, I broke down and ordered a DCC Specialties PSX-4 solid-state circuit breaker to go with my On-Guard-AR auto-reversing circuit breakers. I’ve been planning to do this all along and wiring for multiple zones, but after reading through the PSX documentation, I discovered my understanding of the PSX-4 and how it interacts with AR breakers was a little lacking. I didn’t know that the AR breakers should not be wired off a PSX zone but directly wired to the booster themselves. Turns out with the two reversing zones already protected by an AR circuit breaker, I really only needed a PSX-3 because I only have one non-reversing zone per level (1=staging, 2=lower level, 3=upper level, 1R=staging reverse tracks, 2R=St Charles wye to Mayflower). “Snap” – “hey look, now I have a PSX-3 and a spare PSX-1”. . . smart DCC Specialties! Not gonna lie, it was a little confusing to program the PSX to work well with the AR breakers using the Digitrax Zephyr, but I finally figured it out:

  • Set the Digitrax booster to .5 sec short circuit trip using booster instructions (CV 18 to “c” on my DCS100)
  • Solder the Digitrax jumper on each PSX zone per PSX instructions
  • Set the PSX to programming mode via the jumper per the PSX instructions
  • Ignore the part about setting the PSX address unless you need the PSX to respond to “on/off” or other special commands from the DCC (If you just need it to be a circuit breaker, you don’t)
  • Connect a single PSX zone directly to the Track A / Track B from the Zephyr
  • Turn the track power on on the Zephyr
  • Put the Zephyr into “OPS Programming” mode
  • Select CV55 (“CV”, “55”, “CV”)
  • Press “1” and “CV-W” (add delay to the PSX so the AR zones will trip/reverse first)
  • Select CV65 (“CV”, “65”, “CV”)
  • Press “80” and “CV-W” (set delay to 10ms which works for my setup)
  • If Zephyr shows “Busy,” exit programming mode and try CV65 steps again
  • Set PSX to ops mode via the jumper per the PSX instructions
  • Repeat steps for additional PSX zones

Lower Level Wiring BusI encourage you to read all the instructions first and choose your own adventure–just sharing what worked for me.

Finally, before I lay subroadbed and track for the lower level, I had to add the wiring bus, or in this case, two wiring buses. Two are needed because the St. Charles wye needs a reversing circuit, and the reversing district carries over all the way to Mayflower. Lots of drilling holes, cutting open Romex, and pulling heavy gauge wire through. I still have to make the little pigtails for feeders, but it’s mostly done. Shouldn’t be long before I’m laying track on the main level!

Fascia Pockets for Operators

My undergrad is in Human Factors Engineering, the science of designing things so people can use them easily and intuitively. Though I’ve never been a Human Factors Engineer in my work, I enjoy applying the principles I learned to my model railroad. The first step of human factors for a layout is usually the space for operators–designing aisles wide enough to accommodate your people and give them access to the areas of the layout they’ll need. The next step is figuring out what other needs for space they’ll have while operating. One of those space needs is a place to store their “stuff” they use while operating–enter the fascia pocket!

I’m continuing my practices from my former Interstate RR layout. Upon being assigned a train, each operator will be given a clipboard with their train information (location, engine number(s), throttle assignment, etc.), instructions on how to work the train, any applicable train orders, a map/diagram of the layout, a switchlist, a pencil, and a decoupling tool. The operator will need this clipboard throughout the session, and since I DON’T want operators setting their clipboard on top of the layout, it’s important I design in convenient spaces for these clipboards.

Fascia Pocket - almost finished
This is what a nearly finished pocket (still missing paint) looks like–this one will store a clipboard up top and timetables or switchlists below

Once I put in the first section of main-level benchwork above the staging level, I had a nice ~8.5″ space between levels that might work for this purpose, but I needed some way to keep the staging tracks safe. I decided to build clipboard pockets over the staging tracks since trains only need about 3.5″ of the 8.5″ for clearance. The clipboards are 9″ wide and 13″ long, so I’m making each clipboard pocket 10″ wide and 12.5″ deep–this will ensure the clipboard sticks out about 1/2″, just enough to ensure the clipboard is easy to grab without impeding on the aisle or snagging on operators.

To support each pocket, I need a base about 3.75″ tall between the staging base and the pocket. I’m using these as storage pockets for useful things for operators as well. The pocket depth depends on how far the staging tracks are set back from the fascia. In some areas, I can make pockets 12″ deep for papers. In other areas, I can make pockets 4.5″ deep to hold extra switch lists, timetables or hand-outs. Some areas where the track is close only allow a ~1″ pocket. . . hmm. . . I know, that’s perfect for storing extra 9V batteries for the wireless throttles!

The next step was figuring out where to put them. I wanted them in spots useful for operators, but they also needed to be away from the yard ladders in staging and spread apart enough to allow easy access to all staging areas. I decided on five locations that line up well with the action on both decks. A sixth area is formed by a counter top a few inches under the benchwork for Mayflower. There will be a pocket within 2-3 feet of an operator for about 90% of the layout.

Clipboard Pocket Locations
Fascia Pocket - positioning
Overview of two pockets showing the ample space between them for accessing staging

I made my pockets from 1/2″ MDF–strong and smooth. To secure the base to the staging level, I mock fit it in place, drew an outline, and used the outline to drill pilot holes through the subroadbed. After gluing the base pieces in place, I went back and drilled up through these holes into the MDF to lock it in place. Next, I secured the deck for the clipboard pocket to the base using glue and countersunk screws since the back would be suspended over the staging tracks. Finally, I glued the side pieces on top of the clipboard deck to finish the pocket. While I could have made the side pieces solid and mounted the clipboard deck inside them, I figured this method would be more durable as there’s no way for the deck to break away from the sides.

These pockets are certainly nothing fancy or extraordinary, but I find its often the small, ordinary things that make a difference. In this case, I’m hoping the ability to easily find a space to put their “stuff” will make operating on this layout just a little more enjoyable and stress free.