Category Archives: Structures

New Branch Up-and-Running

Kemmergem Tipple Mock-Up
Newly completed Kemmerer Gem No.2 tipple mock-up on the Gin Creek Branch

I’ve been working feverishly on the Gin Creek Branch which served the distinctive two-track loader at Kemmergem, VA. This branch occupies about 1/3 of my upper deck and is the first piece of the upper deck to be operational. I went out of my way to make the trackwork look like a well-used and minimally maintained branch with some crooked ties and rail. This branch is also laid out on an S-curve where you can look all the way down the straight portion where the loader will lie between the curves, and because of this curve, I think this might become the “signature scene” for the layout.

First Train on Upper Deck
Here’s the first train on the upper deck rolling through the junction onto the Gin Creek Branch at Turners Siding

 

First Train on Upper Deck
The tail track just barely holds two GP38s and two triple hoppers

To get things operational, I had to run the DCC bus wires and install manual switch mechanisms. At this point, I was able to run the first train to the upper deck and make sure everything worked. It’s a cool arrangement with double-ended loader tracks but a short tail track that barely holds two GP38s and two triple hoppers. I’ve also installed a stub track alongside the tail track for the Ralph Baker coal company that built a truck dump here in the late ’70s / early ’80s. Since I’m currently running the ’60s, I decided to use the track to house a small ramp-style loader (which will be replaced by Ralph Baker in late ’70s ops sessions). Switching the track arrangement is a lot of fun and requires some extra thinking since the spur to Ralph Baker is a facing-point stub track, and the only run-around is under the Kemmerer Gem No.2 tipple. You’ve got to place the cars for Ralph Baker and the cab behind the empties for the big tipple and then push them into the right tracks using the loads and empties under the big tipple.

Kemmergem Tipple Mock-Up
View of the south end of the loader at Kemmergem

While it was “operational,” there was still no tipple, and the switches had to be thrown by reaching far under the layout. With an upcoming ops session, I was motivated to give it a bit more finish, so I cut and painted the fascia and put in the switch controls. I also took the opportunity to install my fast-clock controls in their permanent place, a little cut-out in the fascia. What’s a mine run without a loader, so I created another temporary “paper doll” mock-up from cardstock prints and foamcore for the Kemmerer Gem No.2 tipple. This is a really cool looking loader that has two loading points with a long covered conveyor between them making the thing look a bit like a corrugated diplodocus dinosaur. I created some drawings of a slightly compressed version based on a series of photos from the ’50s-’90s (it didn’t change too much) including some great detail shots by Robby Vaughn. While I was at it, I created a little temporary dock for the Ralph Baker spur (which I’m calling “Darbyville Dock” for the ’60s sessions). A couple of paint brush handbrakes on the steeper spotting locations, and the branch was ready for an ops session!

Kemmerer Gem 2 1998
The prototype Kemmergem tipple shot by Robby Vaughn in the late ’90s

 

Kemmergem Tipple Mock-Up
Gluing the prints onto foamcore for the tipple

 

Kemmergem Tipple Mock-Up
Mock-up for one of the two loading points waiting for a paper roof

 

Darbyville Dock
Mock-up of “Darbyville Dock” at the end of the Gin Creek Branch–note the gnarly trackwork on the tail track to the right

 

Fast Clock Controls
Here’s the finished fast-clock control panel recessed into the upper deck fascia.

St Charles Depot (kind-of)

St Charles Depot mock-up finished
The St Charles local slows to pick up orders from the operator at the St Charles depot

This update is proof positive that I will do anything to procrastinate on building scenery… Of course, in my mind I’ve justified this delay as important because I need to be able to visualize the scene in St Charles before putting in the basic landforms. Sure, let’s go with that very logical explanation!

Several months ago I shared my plan to build mock-ups of the major structures on the lower level, the first of which was the Mayflower tipple which has appeared in many updates since it was built. I don’t want to build the permanent structures until construction on the upper deck is complete, but I’d like to have some of the key buildings represented both to visualize scenes and to give operators something better than just a block of wood to represent the buildings they’re working. Creating these mock-ups also requires me to build scale drawings (in MS PowerPoint) which, in theory, will make it MUCH easier to build the actual structures down the road. Of course, PowerPoint makes it easy to add colors and textures, so why not?

St Charles Depot
One of the few pictures I’ve found of the St Charles depot–it was darker, but I lightened it to see more of the details (photographer unknown, please tell me if you know so I can give proper credit)

The St Charles depot burned down in the late ’70s, so there are very few photos of it. I worked with a couple of grainy shots and one grainy overhead image to get the basic size and layout. I used scanned plans from other Southern stations to get basic dimensions and features and to serve as a template for building the drawings in PowerPoint. I don’t have the space to model the station full-size, so I aimed for about 90% to scale on the length and about 70% on the width. The toughest part of the drawing was getting the cut angles for the roof right in a flat rendition so I could get the 3D shape correct. It required some trigonometry that made my brain hurt, but in the end I got a double-pitched roof with 22- and 35-degree slopes, pretty close to the drawings of other Southern stations. I omitted the curved roof windows for the mock-up as they would have been a pain and aren’t important to visualizing the scene. The detail like windows and siding is just lines and shapes drawn in PowerPoint, and the roof shingles are a texture I found online. Don’t ask me why the door on the track side of the station is suspended on the wall with no ramp or dock, but as you can see on the prototype photo, it is!

St Charles Depot mock-up foam core walls
I used 1/4″ foam core to give stiffness to the basic structure

I learned from the Mayflower tipple that using ordinary paper results in the glue bleeding through and staining the color, so I printed this one on heavy paper, almost card-stock and about as thick as my printer would handle. I cut the basic walls out of 1/4″ foam core using the drawings as a template to give it rigidity, but the roof is just the card stock. I built a base and the loading dock on two sides using layers of foam core and covered parts with print outs of boards and vertical siding cut to shape. A couple of tiny “ST CHARLES” signs made from folded paper completed the mock-up. Everything is assembled with basic white glue. After it dried, I set it on a piece of plywood I attached to the sub-roadbed using spacers to level it on all sides–I figure this will make it easier to install the final structure level.

Now that it’s in place, I see that I need to raise the roof probably another 3/16″ which will be easy enough to fix in the final version [update, I raised the roof another 3/16″ as seen in the first photo, and it looks better]. For now, though, it’s great to have something anchoring the scene in St Charles, and I’m sure it will perform many years of dutiful service as I’m very slow. Oh, and if you know what colors the St Charles station was painted (there are clearly two), please leave a comment!

Semaphore in St Charles

St Charles semaphore in action
The semaphore in action indicating the St Charles Local has no orders to pick up before proceeding eastward to Appalachia
St Charles semaphore stop indication
Blade down and red light indicating both east and westbound trains must stop at the station to sign for orders

I had one major project to complete before completing the scenery base on the lower level, and that was the train order signal in St Charles. I’ve been putting this off for a couple of reasons. First, I’ve never made a full working semaphore before, so I wasn’t sure exactly what I was taking on–the dwarf semaphores I made a while ago gave me a significant head-start, but this was much more complex. Second, I don’t know exactly if the Southern used a semaphore in St Charles – or if they did where it was located – so I was hopeful my procrastination would result some evidence. Alas, I finally just had to bite the bullet and build the thing! Yes, I know there are commercially available semaphore kits, but what would be the fun in that? I’m a glutton for punishment, and I had a bunch of brass stuff laying around, so why not try to scratchbuild one?

I know with 100% certainty that the station in St. Charles had an operator who passed train orders to Southern and L&N crews working the branch. There is both photographic and timetable evidence for this. In the era I model, it was typical for a train order station to have a three-color signal of some sort indicating “red” (stop to sign for orders), “amber” (slow down to pick up orders) or “green” (no orders – proceed), and a three-position semaphore was common. On most stations, the semaphore is built right alongside the station’s office with the control levers inside the station. However, pictures of the St. Charles station clearly do NOT show an adjacent semaphore or any other type of signal. The only thing I can think is that the Baileys Creek Branch to Mayflower cut off the St. Charles main a couple hundred yards geographically south of the station, and train movements on this branch were controlled by the station–perhaps the signal was closer to this junction to allow train crews to see it an heed from both the St. Charles and Baileys Creek Branches. So, that’s what I chose to model!

St Charles semaphore first assemblies
After finishing the semaphore blades, I attached a .015″ brass wire via solder and made a spacer from brass strip folded on itself. I used the same brass strip to make swivel bases for the blades on both sides of the pole

Like my dwarf semaphores controlling access to the coal branches, I wanted the semaphore to be fully operational including lights, blade movement, and fascia-mounted controls. The first job was making some semaphore blades. I did this by making an outline of an upper-quadrant blade in PowerPoint, scaling it to 1:87, and printing it onto a label. After attaching the label to some thin sheet brass, I drilled holes for the lenses, pivot point, and control rod and cut out the blade with scissors, using a file to clean things up. I soldered on the pivot rod, .015″ by bending one end, inserting it through the hole, and soldering it to the blade face. Next I added a small spacer for the blade onto the rod made from a piece of small brass bar bent on itself with a hole drilled through. I painted the blades flat black and insignia red for the blade end. The back of the blade got some silver Sharpie following pictures I’ve seen of other Southern stations. The lenses are just short pieces of fiber optic with one end melted into a round shape using a soldering iron (just hold it near the end of the fiber optic), attached with CA and colored with kids markers.

St Charles semaphore ladder added
The next step was to add the brass ladder stock and connect it to the mast with U-shaped .015″ brass wire

The mast is a piece of 3/32″ brass tube. I made two mounting plates for the top out of brass bar, filed flat spots onto the tube, and attached them via solder. Next I added some guide loops for the rods that would go from the ground to the blade. I bent something resembling the shape of Saturn out of .015″ brass wire and soldered it tightly around the mast, using a semaphore mast diagram printed to scale as a guide for positioning, three guide loops total. This resulted in two U-shaped loops, one on either side of the mast. I finished the loops by soldering a small piece of wire across each U to make a smaller hole to the outside away from the mast. My soldering skills are not great, so this was a lot of ugly blobs until I took a file and cleaned things up. I added a piece of brass ladder stock by connecting it to the top with solder, bending it, and making U-shaped supports out of .015″ brass wire which I soldered into place in three locations and cleaned up. I painted the mast assembly flat black and then used a combination of silver Sharpie and silver paint to finish it.

Now I was ready to put the blades onto the mast. I fashioned some control rods from .015″ steel music wire, inserted them into the blade holes, and ran them down the guide loops on each side. After inserting the blade pivots into the mounting plate, I bent the brass rod 90 degrees to hold each blade in place while allowing it to pivot freely. I made the base from scraps of plywood (see pictures) and drilled a 3/32″ hole for the mast, two adjacent 1/16″ holes which I lined with 1/16″ brass tubing for the control rods, and a larger hole for the ladder to slide into. I press fit the mast into the holes with the rods going through their brass tubes. Then I ran a piece of fiber optic cable down the tube. I first tried to file one end of the fiber optic at an angle to get it to shine through the blade lenses, but this didn’t work well. I ended up holding the fiber optic over a spare piece of 3/32″ brass tube which I heated with a soldering iron. When the tube got hot, the fiber optic bent itself over the tube in a perfect curve which still conducted light well. A little more heat to make a rounded lens at the end, and I had my “light” for the blades.

St Charles semaphore slide switch mechanism
Here are the mechanisms made from 3-way slide switches. Not only do the switches route power to the bi-color LEDs, it also connects the lever to the signal mechanically and provides the detents for movement

I wanted to use .062″ steel music wire (the same stuff I use for manual turnout controls) for the fascia-mounted control rods, so I crafted two triangular levers out of thick styrene hinged at one corner to convert the horizontal control rod movement into vertical movement for the blade control rods. I covered this in some detail with the dwarf semaphores, so I won’t cover it again here. With the mechanism in place, I mounted the base and semaphore assembly in place on the layout. Next, I worked on the control rods made from 36″ pieces of .062″ steel music wire. Where they would cross through benchwork, I drilled 2/32″ holes and lined them with brass tubing. I was able to get a pretty good bend in the control rod without it kinking this way.

St Charles semaphore finished from lever to signal
Here’s the finished semaphore from levers and lights to the blades in the background

The heart of the control rod mechanism is a 3-way slide switch. I bought a handful of these for the dwarf semaphores because of their longer throw, but it turns out they were exactly what I needed to control both the throw and the lights for the full semaphore. I’m using 2-lead, bi-color red/green LEDs for the lights. Controlling the red and green is easy enough with DC and crossing the +/- leads on two of the poles on the switch to get the red and green on the end throws of the switch. For the amber, I wanted to use the AC current from my track power. It took a bit of thinking through the use of the 16 leads (it’s a 4-pole slide) to figure out how to route both AC and DC power to the same LED without ever crossing the streams, but the arrangement seen hand-drawn on my cheat sheet (see gallery below) works well. I secured the rods to the semaphore to the slide switch by bending them 90 degrees and inserting them into a hole drilled through the switch control. A second rod inserted through a second hole in the switch control was run through a piece of 3/32″ brass tubing to the front of the fascia where I capped it off with a wood ball (smaller than the ones I use for switch controls so operators can tell the difference).

The final step was to run LEDs from both switch mechanisms to the fascia where I used stick-on letters and graphic tape to make a little drawing of a semaphore in each direction alongside the track diagram–the operators can look on the fascia to see the color indication if they don’t want to use (or don’t understand) the blade positions on the layout. Finally, I added a second clip to hold orders under the fascia so that the old clip is now “train orders westbound” and the new clip is “train orders eastbound.” So far I’m really happy with how the semaphore looks and now it operates, and it was really fun to build. I know it will add yet another aspect of prototypical operations to the layout as crews now have to read signals to see whether or not they need to pick up orders.

Mayflower Tipple Mock-Up

Mayflower Tipple Mock-Up
The final tipple mock-up in place on the layout showing its size relative to the benchwork and hoppers

I’ve finally started laying subroadbed onto the main level of the layout, and I’ve chosen the section between Baker and Mayflower as my first scene (see track plan). Mayflower is the first of four large tipples on the layout, so to make sure I’ve got proportions and track spacing right in the plan, I decided to build an HO scale mock-up from foam core and cardboard first. I’ll just warn you, this is not a time-saving process, but it certainly helps you visualize a scene and make adjustments before building more permanent structures and track. Because this was the first and the only large tipple on the lower deck where vertical spacing would be important, I decided it was worth the effort.

Mayflower Tipple Pics
This is all of the photographic material I had from which to draw and build the Mayflower Tipple

Step 1 – Research. I’ve made a commitment to modeling the tipples as closely as possible (rule: no Walthers New River Mine allowed–it’s not a bad kit; it’s just over-used and too recognizable). The trouble is this area is not well documented by photos, so there’s a lot of guesswork and extrapolation involved. The first resource I had was a track chart that showed four tracks under the tipple, a medium-sized operation. Next, I found an aerial photo from the 1960s that showed the basic footprint of the tipple and the distinctive portion of the tipple connecting the tipple to the mine that sits 45 degrees to the tracks. Finally, I found a single grainy photo of the front of the tipple and a painting of it from a post card that someone had posted to Pinterest. With these resources, I had enough to rough-out a drawing.

Step 2 – “Scale” Drawing. Regardless of whether or not I’m building a mock-up or the final model, I need some sort of scale drawing to build from, and for tipples that were one-of-a-kind, actual drawings are very rare. I use the word “scale” here loosely because none of the research offered any clear dimensions. Still, distances between tracks and height above hoppers can be estimated, so I did my best. To make the drawing, I used my favorite drawing program, MS PowerPoint. No, PowerPoint isn’t designed for this, but it’s easy to use, and you can draw lines to specific dimensions and angles. I would work on one side, matching it as best I could to the photos. Then I’d copy relevant bits from the one side to use as size references for the next side until all the parts were drawn. Some sides were longer than a piece of paper, so I drew these as two separate drawings I could glue together later. The tricky part was the photo and postcard showed two different time periods for the tipple. The photo showed a section added to the front over two tracks, so I had to figure out how this might have worked in concert with the tipple represented in the postcard.

Mayflower Tipple Drawing 1
Line drawing of the front of the tipple showing the 2″ track spacing and profile

I decided to draw windows and corrugated metal siding on it as well. This was a simple matter of making a generic window and copy/paste it in place. The siding was just a texture I found online and copied into scale sheets to place behind the drawing (use the “send to back” function on right click). When everything looked decent, I printed it out.

Step 3 – Building the Mock-Up. For material, I used black-on-black 1/4″ foam core picked up at the local big box hobby store. It’s easy to cut and work with and has enough rigidity to make a durable structure. I cut out pieces of the drawing and then glued them to the foam core using normal white glue. Where I have a corner, I needed to pick one wall to recess the width of the foam core so they won’t overlap (i.e., when gluing the drawing would overhang the foam core by one foam core width). As you can see from pictures, the glue caused a little discoloration and warping of the paper, but hey, it’s a mock-up. Next I cut along the edges using a metal ruler and X-Acto blade. The trickest part by far was cutting the intricate frames of the leg pieces (5 total). A mock-up doesn’t really require this level of detail, but I decided it was important enough to judging the look of the tipple that I spent an extra 3 hours or so cutting these out. The glue and paper caused some of the sides to bow a little, so for these I cut out 1/2″ wide strips of foam core to attach perpendicular along the back and bring them back into shape and provide lateral strength. This required laying a heavy book on top while it dried, but it worked well.

Mayflower Tipple Mock-Up Assembly
Tipple mock-up in progress–I worked one joint at a time

With the pieces cut out and strengthened, I started gluing them together. I worked on one corner at a time and used little pieces of square foam core to keep the corners square. I added structural pieces of foam core wherever needed to keep things sturdy. Again, the trick was to work one joint at a time (no more than two) instead of trying to build it all at once. The glue dried sufficiently in about 30 min, so I’d just come by every 30-60 min and glue another side on. Finally, I made the roof out of corrugated cardboard salvaged from a box–it’s a little thinner than the foam core but still has sufficient rigidity. After test fitting the roof pieces and making adjustments with the blade, I glued on the roof pieces–this is tricky because you have to worry about a lot of edges at once.

Step 4 – Evaluating the Scene. With the Mayflower Tipple mock-up complete, I could now mock-up the scene on the layout and see where the tracks would go, how tight the spacing would be for hoppers (adequate), how far I could bring it out or push it back in the scene, how much space I would have with the upper deck, etc. As it turns out, the tipple fits perfectly and doesn’t need any adjustment, but it would be easy to make cuts and repairs to the mock-up to try different things that would be a lot tougher to do on a final model. Any changes would simply be added to the drawing to use for the final model.

Conclusion. While I could have been halfway done with a permanent model in the time I built this mock-up, I now have the confidence in my drawing and in the scene to build the final model. Besides, it will be a while before construction on the upper deck in this area will be complete enough to install a permanent model, so in the meantime, the mock-up will give me and other crew members a good stand-in to enhance operations that I don’t mind getting a little roughed up. Beats having to use your imagination when switching out empty and loaded hoppers!