NTS & B Merry Chrismas 2008

Another year has passed, and the layout is still in process. I'd like to wish everyone a merry Christmas, and happy new years. Wait-is that my present falling off Santa's sleigh ???

NTS & B Helix exit track / graduated trestle complete

The lower helix exit is mounted on the Lionel Graduated Trestle set, bringing the helix loop down to the winter level. At this level, the track will make a raised loop over the mainline yard, and then go back up the other track on the trestle. The winter table top has been repainted white, to faciliate the upcoming snow.

NTS & B Helix Wiring Cleaned up & Norway Pics

I finally got time to clean up the wiring at the bottom of the helix (See June 27, 2008 post). I wanted to try to get the winter layer going so I could set up a Christmas scene, but decided I had to get the helix wiring done first.

Of course, I had to take a little 'detour' to Oslo, Norway for 2 weeks also. Here are a couple pictures of Oslo, and a nice little train store we visited while there.

NTS&B A few Oct 2008 pictures

Scott and Maria were down this weekend, and we got a little camera happy with the upper level. This picture is of Maria standing on her tippy toes looking at the Polar Express from the inside of the Helix.
Here's a good picture of me working on the second (cable stayed) bridge. Talk about having your head in the clouds :)

Here's a picture Maria took of the helix from the inside, looking from the bottom up. I asked her to take one looking down from the top, but for some reason she wouldn't do it :)

NTS & B First 3 of 5 power stations complete

The first 3 power station shelves are completed. Instead of having 1 huge central control panel, I decided to have a distributed power design. Each power station will house all of the transformers to control 1 or 2 levels, and will be positioned close to the tracks and accessories they will control.

The station on the left will control the Subway level. The only additional switches required so far control the station stop, and are fastened to the power distribution box directly above the transformer.

The center station will control the Winter and Helix levels. Switches for the overhead level power and switch tracks will be located on the underside of the bridge directly above this station. The location of the controls for the winter level switches and accessories is yet to be determined, but will be probably on the front of the subway bench work directly over the station.

The station on the right will control the mainline tracks, yard, and switches. The yard power switches are located on the mainline layer directly over the power station. Also housed in the mainline station is the Train Master Command Control (TMCC) module, and the Train Power Control (TPC) module. The TMCC module sends digital commands for remote control to engines that are equipped with the TMCC receives. The TPC controls the track power for 1 track, and can be used to remotely control older 'conventional' locomotives. The output of this TPC will go to a power distribution module in each power station. The module will have switches to select the TPC or local transformer control. This will allow the remote controlled voltage to be switched to any track, to make troubleshooting problems easier at remote locations.

There will eventually be 2 more stations located at the other end of the layout, one on each side of the isle. These will be located close to the operating accessories in these areas.

NTS & B Second attempt on cable stayed bridge

Am trying a different type of nylon cord. Cord I first used was clear. I was trying to use LEDs to change the color on demand, but the cords would not show up. The cord on the side closest to the camera is light blue weed-eater string. Shows up a little better in they daylight, but no help with the LEDs. So much for that idea. I plan on restringing the other side with the blue cord when time permits.

NTS & B Second power station started

Second (of 5) transformer shelf is built, waiting for paint. Shelf is in approximate position. Leg brace will have to be trimmed before if will fit where it is supposed to. Unit is app 18 inch wide, 30 inch tall, and made out of 1x12 with a plywood backing.

NTS & B last winter level table finished

The last of the winter level tables is now complete and installed. Need to paint some supports. Gaps between the 2 layers will eventually be filled in with foam 'stone' walls, or a steep rock wall. Module is approximately 3 ft x 6 ft, and made out of 1x4 and 1x2 frame covered with 1/2 inch 4 ply plywood.

NTS & B Second major bridge started

Sep 2008 - Decided that the bridge for the second room crossing should be a different then the suspension bridge used for the first one. This one will be a 'cable stayed' type. This is the first tower up, with one side strung. I am using nylon line, with the plan of adding colored LEDs or wheat bulbs to change colors on the lines (at least that is the plan).

Some videos

Use the "YouTube Channel" bar on the right to view other videos like this one.

The new bridge is FINALLY open on the North Pole Line. This is video of the Polar Express topping the helix and crossing the bridge.

NTS&B Suspension Bridge Construction Notes

The bridge is now finished. The first couple pictures are of the completed bridge. Pictures of the construction are below and in order of construction.

Measurements / Construction Notes:

• Main (Horizontal) cables were made from 1/8 in steel cables.
• Vertical cables are made of cotton embroidery thread which are fed through #2 13/16 inch long eyelets, wrapped around top cable and tied. The thread is sightly stretch, so holds in place very well. A dab of hot glue was applied to the threads on the steepest part of the cable to make sure it doesn't slip. Caution, do not use super glue, as it bonds the fibers of the thread, and the thread becomes totally brittle.
• Eyelets are deck spaced every 2 inches on the bridge deck, and start at 2 inch from edge of tower
• Tower is 17 1/2 inch tall from top of deck, and hangs down 1 3/4 inch below deck
• Deck to bottom of lower cross brace between towers is 9 inches, and 14 inches to bottom of upper cross brace.
• Deck is made of 1x12x8, and is app 12 1/2 ft long total
• Overall length of deck from first cord on first tower to last cord on last tower is 120 inches
• Towers are made of 2 1x2's shaved and shaped with a router. The inside one rests on the deck, and has a grove routed in it for the all thread support rod and wires for the blinking LEDS. The cross piece is screwed to the inside pieces. The outside pieces are longer, and hang below the deck.
• Bridge holds 1 O-27 and 1 GScale tracl
  

Initial 1x12 bridge deck with towers

Close up of inside of bridge tower

A template was used to approximate main cables shape. Curve was first plotted on computer, then points measured every 2 inches and marked on template. Screws were then placed at the selected points.

Template in place on bridge cable. Template was clamped in position on the main cables, then the verticals were tied at each screw location.

A cable clamp was used on each end of steel cable to control the tension.
A 1x2 with routed grove was used to hold cable in position.

Eyelets were screwed into bottom of deck at 2 inch intervals to hold verticals. The bridge deck was made from 2-8 foot boards, which were routed and overlapped in the middle for additional support as shown above.

Closeup of knots at top of cable

Tower with outside 1x2 attached.

Picture showing vertical mesurments of tower

Picture showing horizontal mesurments of deck

NTS & B Year 1 and Suspension Bridge Complete

Sep 2008 - Bridge is finally complete (only took 3 months). Wire is run across bridge to provide power to the end of the 0-27 yard, and to add feeder wires to the G Scale track. Picture shows over all layout progress. Village shown on left of picture is lit. Bottom picture shows closeup of village.

NTS&B Table Heights

This diagram shows the final height of each layer on the layout. It was drawn up using Power Point.

NTS & B Track Plan as of 8/16/08

This is the current track plan. Each grid line is 1 foot. Each layer is in a different color. The ceiling layer is brown, Helix is purple, winter is blue, mainline is black, and lowest level is green. The plan also shows the planned locations of accessories and buildings. The ceiling loop on the right of the layout is G scale, and the rest of the layout is 0-27 gauge. According to RR Tracks, there is approximately 956 feet of Lionel Track. I guess I have to figure out where I can put another 45 ft :) The track plan was designed using the RR-Track V4.02 software package.

NTS & B North Pole Loop Yard

Aug 2008-Yard is started on the upper loop. Used Gargraves 0-42 switch tracks with DZ1000 switch machines. Luckily I moved the yard to over the isle, instead of over the lower module, because I have had lots of problems with derailment. Am sending most of the tracks to Gargraves to determine problem with tracks.

Oct 2008 update-Got a call from Gargraves. They were able to duplicate the problem I was having, and are working on a fix. Apparently I am the only one who has used them at the end of a curved track !!!! The tracks I have up there now seem to be working, so I don't know if I will send them back to be repaired or not.

Jan 2009 update-Man am I lucky I moved the yard. I tried a different engine, and had problems with the 1 of the 2 non-replaced switches. Removed them and replaced with modified ones, which are now working. Will send these back along with last other non-modified switch. If that wasn't bad enough, had problems with Z1000 switch machines not completely throwing. Z-Stuff recommended oiling them in the top slot. This has helped. Remains to be seen if totally cures problem. They also sent me an internal wiring mod, but I am not willing to remove all of the machines to make a change while standing on a ladder. At least I wont have to climb over the layout also if I do have to make the change.

NTS & B Winter layer under helix roughed in

July 2008 - The winter layer track temporarily laid in. Pictures show how the winter track with a passing siding goes under the back part of the helix, and how the helix lower loop exits the helix. "Too Tall" Santa (as seen on the car in the picture below) has forced a slight redesign of the passing track under the helix to allow for more head clearance. The 1x4 in the bottom picture is planned to eventually be an Arch Bridge.

NTS&B The rising of the Helix

Here is a summary of pictures and blogs entries made along the way during the construction of the Helix.

I used this pattern to get the most usage out of 1 sheet of plywood. My helix took a total of 2 sheets. For smaller radius tracks, especially fast track, you can lay the track on the plywood and draw it directly. I used a yardstick with a pin hole in 1 end, and 2 holes in the other end at the inner and outer radius points, then used the yardstick as a giant compase

Top view of Helix before legs are attached. Its pretty big (60 inch Diameter).

Bottom view of helix before legs attached. For assembly, I started on the top piece of roadbed, track side down. Then I spliced in the next piece, and the next, which eventually overlapped the first layer. I made sure not to have any splices under the top exit point, so that the slope could be lowered to create less of a hump to the upper level track, and still allow clearance.

Trying to attach legs. Like handling a 6 foot wide 'slinky' toy. Layers are 8 inches, which turned out to be too much.

Roadbed is connected to 2x2 risers using 2 or 4 scew L Brackets

Final result, with layers 6 inches top of track to top of track. Notice how crooked the legs look. Because of all of the grades involved, there is no way to 'eye ball' the verticals. Each leg was plumbed on all sides with a carpenter level.

The unit was tested on the floor for clearance and operating characteristics, BEFORE it was positioned on the layout, which I HIGHLY recommend.

Track wiring completed. Wiring is total over-kill, with connections every 1/4 circle. I attempted to keep all wire lengths equal, to try to keep constant power going up the grades

Side view, partially painted

Wiring connections at top of Helix pole. Used to power ceiling track and accessories

Bolts were placed in the bottom of each 2x2 leg to be used as levelers. Here the helix is resting on the plywood that will be used as the table top underneath it, so the holes can be marked and drilled accurately.

Helix in its final resting place. It only took 5 of us to get it there

Final results

I used 1/2 inch 3 ply plywood. If I had it to do over again, I would use 4 ply. It is stiffer in both directions than 3 ply. I then used 8-2x2s for the legs, 4 inside and 4 outside. I used L-brackets to mount the plywood to the legs. I also put screws in the bottom of each leg for levelers. I don't remember the proper name for them, but they are the ones with 1/4 inch thread on one end, and a Lag bolt thread on the other end. You could also just use Lag Bolts for levelers.

Specs

-6 inches from top of track to top of track

-4 1/2 clearance between layers (top of track to bottom of next layer)

-0-42 inch diameter on inside loop resulting in grade about 4.5 percent

-0-52 inch diameter on inside loop resulting in grade about 3.5 percent

-31 inches total height starting at 51 inches from floor, and ending at 82 inches from floor

-58 inch overall outside diameter, with 2 inch clearance

-37 inch inside diameter, with 2 1/2 inc clearance

NTS & B Helix Wiring

June 2008 - I decided to keep all of the wiring on the layout as neat as possible, as shown by this picture.

Just kidding. Actually the above picture is the temporary wiring at the bottom of the Helix. The picture below is at the top. The Helix loop is split into 4 blocks - Outside helix, Inside helix, Ceiling level, and bottom level. The inner and outer helix track wires were all kept at the same length to minimize voltage drops. The picture above has all 4 blocks tied together. A plywood panel and terminal blocks will be added as time permits, and will hopefully look more like the picture below.

The wires are color codes similar to house wiring, with Green being track ground and Black for track power. Large white will be used for accessory ground, with Red being accessory wire. The white terminal block with the smaller wires is for low current accessories and switch track power. The wiring on the upper level has to be complete prior to finishing the bridge.