March 2023 Updates - Off to a Strong Start

Winter months do allow for additional modeling time ... so, I've been trying to make as much progress as I can.

Updates since my last post:

The work around my Kedize station continues. I've finished the background building that acts as a background to the station to a point where I've added lights and other minor details. It acts as good photo background for the station. I've also started construction on a foreground building that will most likely be a bakery.

I've also added some additional street lighting to the Kedzie street scene. Another new foreground building is being constructed. A tenant has yet to be obtained, but I'm thinking it might be a reincarnated version of my Elevated Records shop that was on my prior layout.

Also, for the anniversary of the end of service of the North Shore on January 20, 1963, a special charter was arranged for enthusiastic North Short railfans and many pictures were had by all. 

In addition to normal modeling work, I've been attempting to perfect a 3D printed design and application of Chicago Loop L Structure. I'm attempting to make a standardized set of files that can be printed easy and assembled with minimal effort.

The follow is the second version and so far I'm happy with the end result. The structure is printed on two printers: an FDM Bambu Labs P1P in PLA and on an Anycubic Mono X resin printer.

Still in a state of assembly (no glue is used on the below photos - the fit has enough friction to hold it together sufficiently):

Details:

In the above, I still need to add the foundations and some additional bracing.

List of materials:

• FDM Printed on P1P:
• Girders
• Cross girders / bents
• Internal X-Bracing
• Internal zig-zag bracing
• Foundations (not shown)
• Anycubic Resin:
• Columns
• Curved Bracing
• Girder bracing from cross girders / bents (not shown)

The columns are design to fit onto pegs on the foundation pieces. This "locks" the structure to the benchwork without having to actually attach the structure via mechanical means. 

I prefer to use FDM when I can. The post-processing of the resin prints (cleaning and curing) and associated smells of the resin is quite annoying. The quality of the P1P is sufficient for the girders, but I'll probably continue to use the resin printer for columns and bracing details. 

As to how this is printed - at least for the FDM parts all are printed flat to the build plate then sandwiched together:

The girders are comprised of four parts, with the associated joints staggered for strength.

The girders that are on the "inside" of a track's girders are modified in such a manner as to allow for the fitment of the X-bracing and zig-zag bracing. The foundations are one piece which maintains proper spacing between the columns. Each piece also has appropriate rivet details.

The columns, printed via resin, are printed upside down with applicable supports:

Normally I will print the columns in batches of eight columns total on the build plate.  

Below is a screenshot of my work flow in designing the overall structure and eventual station. I build off of previous work and create appropriate structural components as I go along. This is drawn in real size / to scale. When I'm ready to print, I'll split the model into sections that will fit on the printer and then scale the parts down to 1/48 scale, export to STL, and the send to the appropriate printer.

There is a significant amount of trial and error as I attempt to get components to fit together, with detail, and while keeping in mind printing limitations and eventual assembly. The goal is to create parts that will print successfully, require minimal to no supports/post processing, and ease of assembly.

The plan is to use this as a Loop elevated extension to the layout. I'm in the process of designing a station but that is most likely a late Q2 project.

November Updates

 Work as been steadily progressing on the entire layout. Some updates for November 2022 include:

Installation of a mini-control panel for the return loop:

Using Barrett Hill touch toggles, I've made a small turnout control panel for the return loop. Each turnout has its own Tortoise switch machine and then is controlled in turn on the panel.

Each turnout will eventually have its own dwarf signal giving indication of direction. The toggles will control reverse movement signals via manual red/green operation. 

The signals are oversized, but I designed them to accommodate 3 mm LED's.

Stairs to the station platform are finished:

It took quite some time but I've finished the stairs to the station platform. This was a difficult build as I built from the top down. Next time I'll plan better.

I still need to finish the station headhouse, but that may need to wait until after the holidays.\

All station LED Lights are installed and wired:

A huge challenge was getting all of the station lights finally wired. But that task is finally done. Some additional Woodland Scenics Plug-n-play street lights were installed. I'm not too satisfied with these, but they get the job done.

Loop Elevated Structure:

And finally, I've been working on perfecting the design of Loop L structure. The goal here is to make sturdy, yet realistic, yet easy to build structure. This is 80% printed via FDM printing (Ender 3) and 20% via resin (Anycubic Mono X). Overall, there are about 70 individual pieces making up this one foot of structure.

I consider this version 1.0. I need to make some changes and then I'll be adding this to an addition to the layout. Eventually I'll be creating another station. 

 

        

 

Return Loop Installed

 The return loop and mini-yard have been installed in the basement. I can finally store some trains and turn a train around. Eventually I'll be building a terminal station between two of the tracks.

The above picture shows the connection. In this photo, just a piece of plywood bridges the gap.

I've since added a section of elevated structure to bridge the gap. The track in this section still needs to be detailed - add third rails, add guard rails, paint and weather.

The above is a view of the completed structure. At some point I'll add a retaining wall to cover the end of the return loop module. 

Turnout control is via Touch Toggles and I've created a rudimentary control panel. The turnouts are controlled via LED touch toggles in the track plan, the two toggles on the left are pending wiring for reverse movement signals. I envision having to manually release an outbound train via manually toggling the signals. 

Some never finished projects seem to hang out now in the yard:

I've also been trying to finish the structure for the stairs. This has been rather difficult as all the parts don't quite fit as well together as I'd like. I'll be adding roofs and lighting to the stairs. Right now I'm just trying to get the structure in place. 

And finally, some of the wood cars paid a quick trip around the layout:

Work Progress on the Return Loop Module

 Throughout the summer, I've been working on completing the return loop module. Due to space constraints, I've been constructing the module in the garage.

The radius of the loop is 16" and the turnouts are a mix of # 4's and 2.1's, which match the 16" radius.

Turnout control will be via Tortoise switch machines, controlled by Barrett Hill Touch Toggles.

Each turnout will have its own signal for routing. These are 3D printed from my own design.

I'm currently wrapping up the wiring and ballasting the track. Hopefully I can have this in the basement in the next month or so before the weather turns cold!

New Return Loop Module

 I've taken a break from working on the Kedzie Station to start the trackwork on a new return loop module. This will attached to the right of the station module. However, the trackwork will be at ground level as I didn't want to try to make all elevated structure. Also, I'll be including some storage tracks. This "could" be considered a very condensed replica of the Douglas Park's terminal and shops. I haven't decided if I'll include a passenger platform.

The turnouts are a mix of # 4's and # 2.1's, those will match the 16" radius return loop. I'll be a tight fit but space is limited.

I'll be moving my bookcase and adding the module at the top of the following picture:

And one more overhead view,

Slow grind for the staircase

Work has kept me very busy the last few weeks so not much progress to report.

I've been slowly grinding away at the staircases. Its been a challenge as getting everything to fit together has been difficult. I've changed designs several times so far to try to get everything to fit.