Construction
My modules are going to be built to the Calgary Free-mo standards. They have a recommended way to build the modules and the frame work standards are listed below. Because most of the track in the area I am modelling is either three or four track I need to make adjustments for that. In addition I will be making modifications to the legs, so that the height can be set at a variety of different heights: 42", 45", 48" and 50". (all +/- 1") These heights match various standards for Free-mo modules, including Calgary Free-mo, Ottawa Valley HOTrak, and Northern California Free-mo standards.
"Frame work" refers to a module's structural frame including endplates, interior supports, legs, and braces. There are no requirements to use specific materials or construction methods; however, the basic trade-off is sturdiness versus weight. To date, frames have been built from dimensional lumber, high-quality plywood such as birch, and medium-density fiberboard (MDF). Other more exotic materials are possible but have not yet been used by Calgary Free-Mo (wood/foam sandwich, aluminum, honeycomb structures, etc.). We have had great success using a frame constructed from 3/4 G1S plywood. See drawing on the left.
Generally, dimensional lumber is discouraged due to warping issues.
Height:
The nominal module height measured from floor to top of rail shall be 42", adjustable from 41" to 43"
Suggestion: the height adjustment range of 2" is a minimum; a larger range is acceptable and recommended. It must be kept in mind that this is a variation on the generally accepted 50" rail height used by most other Free-Mo groups.
If any of the Calgary members wish to participate with another Free-Mo group, they should be aware that they may have to have a taller pair of legs.
Width, Length and Shape:
See Endplate specifications (below); otherwise free. As a note for ease of use, it should be noted that a module over 6' in length becomes very hard to handle by one person; both in size and weight. If you plan to build a module over 6' in length you should consider making it in two or more sections.
Endplate - Multiple Track
The image on the left is an example of a module endplate for two tracks.
Multiple track endplates are 26" wide; the two tracks are centered 2" apart, each centered 1" from endplate centerline. Rail tops of both tracks are at the same height, 3/8" above the scenery top surface.
Endplates MUST be parallel to each other, and perpendicular to track both vertically and horizontally. They must be as flat as possible (e.g. not bowed, twisted, etc.). Material must be solid and sturdy for C-clamping to adjoining modules.
Track spacing may deviate from 2" centers within a module (e.g. broader through curves).
See NMRA standards for spacing specifications.
Some legacy modules have more than one track at a 24"-wide endplate. Mating them with 26"-wide double track modules results in small fascia offsets.
Mating 24"-wide single track and 26"-wide double track modules results in small fascia offsets.
Legs and Longitudinal Bracing:
Each module must have legs that support the module. A module must stand secure and level independent of other modules. Each leg must include vertical adjustment of plus and minus 1" minimum to compensate for uneven floors (e.g. rail top height above floor must be adjustable minimum of 41" to 43"). If painting the legs use the same paint as the fascia.
- Design and construct legs as part of the frame, making them an integral part of a module structure.
- Install cross- and angle-bracing on legs for added stability.
- Add angled longitudinal braces to prevent module from swaying parallel to the track. This stabilizes the module for fine adjustments during setups, and when working on the module during construction.
- We recommend using Lee Valley Catalogue #01S04.05 Panel Brackets (sold as a set of 4) c/w catalogue #01S06.04; 4" long Leveler Feet. 'T' nuts with machine bolts are acceptable. Ensure that the bottom of the feet have a means of attaching a protective base to prevent damage to flooring at any set up locations.
- Cut leg cross bracing once legs are installed in pockets (see frame drawing). This will ensure that the legs are correctly spaced.
Fascia:
Fascias must be smooth and made of a solid, sturdy material (plywood, hard board, Masonite, etc.). Fascia must be 6" tall at the endplates continuing this height 6 3/4" in from the face of the endplates. If the module is flat across the entire length, the fascia will be 6" tall from top of module to bottom of fascia. If the module has rivers, hills, canyons, gulleys etc. that show at the edge of the layout, construct the fascia accordingly to provide a neat and clean edge appearance and a means to attach skirting. Mount a 3/4" wide strip of "Velcro" loop material the full length of the module on both sides. The bottom of the strip to be 6" down from rail height. Used for attaching skirting.
End plates and fascia shall be painted Behr Satin Enamel Wall and Trim, Behr base number 513 Deep Base; Mayan Green* All other exposed wood, frame work or base scenery on the top surface to be painted with Behr Flat Super Scrub Dried Bark.* It should be noted that the top of the module must be painted with the Dried Bark so that if any other scenery products happen to come off, there will be no bare wood showing.
- Avoid protruding items like toggle switches to prevent accidental damage or injury to operators; recess these items into cutouts in the fascia.
- Label both module sides with name of module. Lamecoid plaques will be made available at a nominal fee.
- Label electrical switches and other operational items. Brother "P-Touch" labels are acceptable. Confirm print size.