Grain Elevator Complex - First Step on a New Layout

I have been thinking about a new layout a lot lately, and while I don't have the exact details solidified, there are a few things I know for certain.  One of those certainties is that I am going to have a grain elevator as a major focal point on the new layout.  I've been around grain elevators my entire life, and while Walthers does have a decent model, it falls short of what I consider to be a suitable structure for my layout.  Much like my Orin Line years ago where I ditched the Walthers flood loader for a length of PVC pipe, I am doing the same thing again for the grain complex.  Many grain elevators today are a combination of older concrete structures with more recent steel bins added for more capacity.  Just watch corn and soybean harvest here in he midwest and you will see why that extra capacity is needed.  Many facilities also have areas where they pile corn on a giant slab and cover it with plastic until they can get trains to haul it out during the winter months.

My design will be a combination of an older concrete structure, newer steel bins, and the typical tower dryer like the one you see in the photo below to the right of the concrete structure.  Of course to complete the grain complex I will need a scale, grain sample probe, unloading pit for both trucks and rail, and various trusses and structure components to tie all of the pieces together.  

Here is the elevator I haul to often in Council Bluffs.  It's not a great facility in that it gets backed up quickly due to a single and slow truck pit (grey building to the right of the tower dryer).  But, it does offer unique modeling opportunities.  My grain complex will have a few design components from this site.

One advantage of being close to Council Bluffs is that there are multiple grain facilities to haul to.  Southern Iowa Renewable Energy (SIRE) is a fairly new ethanol production facility that has multiple truck pits and a lot of capacity to get trucks through quickly.  This is important during harvest when long lines can kill productivity.  The photo below shows a newer modern facility owned by Bartlett in a different part of the Midwest.  It is a good example of how steel bins are getting integrated into these commercial sized grain handling facilities, and not just individual farms.  Note the rail load out and the 3 truck pits for unloading.  

Ok, on to my N scale model.  First I decided to start with 1.5" PVC and cut several sections of pipe 8" long.  These bins will be about 100' in N scale.  In order to create a nice seamless joint between each bin, I decided to run them through my table saw to make two flat sides.

Here you can see the PVC bins with flat sides, ready to be glued together in a line.

I used PVC cement to glue the pieces together, making sure I was working on a flat level surface so that the line of bins were perfectly straight.  

Even though I tried to mate each bin to the next without a gap, I still had some spaces between the bins.  I found an easy solution with a strip of .010 x .060" styrene.  I simply cut them to the same 8" length of the bins and secured with CA, which bonds to both styrene and PVC very well.

Here is a close up of the bins glued together at their flat surfaces, and a strip of styrene to close the gap.  I am not finished with this step, but it makes a very clean transition between the curves of each bin.

Here is a photo of a line of bins next to a loco and semi truck to give a sense of overall size.

In addition to the concrete bins, I also bought a length of 6" PVC pipe for my steel bins.  The actual diameter is 6.625" which is about 90 feet in N scale.  With a sloped roof to match the 100' height of the concrete bins, these will hold about 500,000 bushels each.  These look fairly simple now, but I have big plans for these monsters.  My plan is to wrap each with corrugated styrene sheet, add vertical stiffiners, wind rings, and other details.  I also plan to design a roof that I can have 3d printed, although if that doesn't work or the cost isn't reasonable I may have to build it from scratch.  Like I said before, the Walthers grain elevator will pale in comparison to what I have in store for this grain complex.  

I'll throw this in for free.  Looking back over my collection of locomotives, which has been large at times, I have only owned 1 Atlas locomotive.  It was a BN SD60M, and about 15 years ago.  It ran lousy and I sold it not long after I bought it.  Everything else has been modern 6 axle diesels by Kato.  Short story short, I bought this guy the other day for $50 and it runs very well, and am a bit excited to have something a bit different for a change.  I still like modern, but I like when the UP still had red stripes on the sill, and patch units were still common.  I think maybe I'll have to lock my era in the early 2000's?  I now understand all of those modelers that have an interest in a specific era.

That's all for now.  I guess this shelf layout idea that is finally coming to fruition is starting to pay dividends in more ways than I previously thought.

Oh Yeah, I Like Trains Too - New Layout Started

I was nearing crisis mode there for a moment.... no posts for a almost a month, more trucks than I can shake a stick at, and over a year without a layout of any kind.  Well, I am back on track tonight, with a generous dose of layout construction to tame my N scale addiction.

I decided on a 3'x8' footprint this time, with a 6" extension on part of the front.  This will allow me to fit it easier into the space in my garage.  I cheated on the frame construction in that I used 1"x6"s ripped instead of using plywood.  I am a firm believer in using plywood as dimensional lumber, but with the limited amount of material that I needed for this project, I decided to take my chances in finding a couple of boards that didn't resemble firewood.

Like all of my previous layouts, I added caster wheels so I could move the layout around in my garage.  The difference this time is that the casters happen to be connected to a 300lb  tool cabinet.  I bought a cabinet several months ago to store my tools, and liked it so much that I decided to buy another just for trains.  I like the idea of having lots of storage right below the layout.  It's not a Snap On, but it's a nice heavy unit from Harbor Freight.  Although they do sell a lot of cheap tools, their tool boxes are actually made with heavier material than some competitors and very reasonably priced.  To get the top of the layout at an appropriate height, I built a pedestal with 2"x6"s on edge that fits snug in the top rim of the tool box.  When I go to train shows, I will simply lift the layout off the pedestal and load it.

So there you have it.  An unconventional method of layout construction, but practical.  I don't know that I have ever seen this done before, so extra points for originality.

UP Council Bluffs Sub - More Revisions

My life must be changing, because with as many things as I have going on in my life now, I don't know how I managed to build my Marias Pass in less than 18 months.  I do recall several nights up to and past midnight working on trees.  That said, I know most of my precious hobby time has been spent designing and finishing trucks and trailers, and I continue to neglect the new layout project.  Of course I am the type of person that if an unfinished project becomes stale, or goes too long without proper attention, I lose interest, and sometimes abandon it completely.  My Council Bluffs Sub has become victim of that, and I am already looking at different bench work arrangements.

As you might recall, I had 2 8' table sections built and waiting for final touches before laying out track lines.  I have already dismantled one of the two tables, and I really like how the remaining 8 foot table fits in my garage space.  I had toyed with the idea of a 10x4 foot "L" shaped shelf layout, and wrote about that a couple weeks ago.  Further noodling on this subject has produced yet another idea.  This time it is an 8x4 "L" shaped layout, with a permanent shelf, and enough staging on the backside of the backdrop for a possible scenic'ed space rather than simple hidden staging.

My logic is as follows:

I like the idea of a small simple shelf layout that I could finish in a reasonable amount of time without it becoming stale.  I imagine that my 3d design and printing efforts will continue into the foreseeable future, and I doubt I will have large sums of time to dedicate to a larger layout project.  This space still leaves me enough room for the industries that I had proposed on the original design, but more condensed.  The purpose of this shelf layout is becoming more of a "diorama" where I can showcase my trucks and trailers, and I am putting more emphasis on this modeling aspect as time goes on.

So here is a mock up of an 8x4' "L" shaped shelf layout.  I still plan to maintain a similar track plan as the previous "L" that I posted a couples weeks ago, with the extension for switching.  The lower shelf was added for storage, and additional bench work integrity if I choose to use smaller lumber pieces to keep the overall structure light weight.

Council Bluffs Sub Design - Revisited

I have been working on 3d printing projects for so long now, and decided it was time to refocus some attention on a new layout project.  As you may be aware, several months ago I created a design for a Union Pacific Council Bluffs Subdivision shelf layout, which would be built in 2 sections for a total of 16' in length.  I even had the beginnings of the benchwork for the two tables.  After some additional thought, I have decided to reduce the overall size of the layout, and change the shape into a long "L".  The main reason for this is the fact that my garage space where my layouts are built and displayed won't accommodate 16' without a car parked outside.  Secondly, the thought of having a seam between table sections just doesn't appeal to me.  So going back to my trusty 10' length, I came up with a 10' x 4' "L" shape shelf layout.  In order to make the plan work, I did add a removable extension.  Another feature that I thought would give this design some added interest is a set of staging tracks behind the long backdrop.  The tracks will be accessible to the front through a hole, hidden by the grain elevator structure.

I used MS Excel to create my last track plan, and since I have been using Sketchup to draw my 3d objects, I thought I would use it for my layout drawing as well.  I have only spent about an hour total on this drawing, so this is far from complete, but will give you an idea of what I am trying to achieve.  I don't plan to put a lot of detail into this plan, as I would rather spend the time building the benchwork and laying out the track configuration on the real thing.  With all that I have going on, I need to find ways to cut corners, without adding risk to the project.

The industries on this layout will be similar to what I designed in version 1, taking into consideration the truck/trailer combos that I want to feature.  Again, this is a sloppy first draft, but using 3d helps me visualize my ideas.  My goal as of now is to have enough of this layout finished to display at the Council Bluffs Great Train Expo in February 2014.  We'll see how far I get.  As always, your feedback is greatly appreciated.

Council Bluffs Sub - Let's Get Going

Tonight I started a very simple mock up of my new Council Bluffs Sub track plan.  I have the backdrop on one of the two tables and hope to begin laying out track lines soon.  Having an actual table to look at is much different than looking at a track plan on a piece of paper.

I know it isn't much to look at, but here is layout section #1 with the elevator located at the back left, meat processing and cold storage on the right, lumber transfer and wholesale, and warehouse in the front.  16' total length is going to give me a lot of real estate to work with, and I'm excited to get started.  The elevator will be the prominent industry on this section at about 4 feet in total length.

Both tables need a few inches trimmed off the front edge, and then I'll add a thin fascia.  The recess below the surface is for hand operated switch levers.

Council Bluffs Sub - Update

I've been focusing much of my N scale time on 3D printing projects, and the new layout was getting neglected.  Recently, I was able to spend some time on the two 8' bench work sections, and they are getting close to allowing me to start laying out some track designs and maybe some building mock ups.

Each section will be 8' in length, and about 20" in width.  I say "about" since the front edge of the layout will have about a 2" variation from end to middle, which can be seen on my track plan that I posted a few months ago.  In the photo below, some of the plywood overhang will get trimmed to the final dimension with a jigsaw.  The remaining overhang will create a recessed area below track level and on the fascia, which will accommodate my planned manual switch levers.  As of now, I plan to use slide switches mounted directly below each track turnout, with a length of piano wire extending vertically through the plywood base, and some type of horizontal connecting rod that will extend forward through the front edge/fascia, with a handle at the very end for manual control.  The slide switch is needed to route power to the frogs.  I used Caboose Industry ground throws on my very first N scale layout, and while they are fun to throw, they are over-sized. I wanted to keep the Council Bluffs Sub truer to scale, so decided against CI.

The backdrop pieces are cut and ready to install, however, I might leave them off until I get further in construction with the layout.  Being able to work from the front or the back of each table section is appealing.  I have caster wheels for each leg, and will be installing those soon too.

Unfortunately, I don't have a nice studio with sky blue walls like Model Railroader does to stage their project photos, so instead I get the wall of my garage.  At least I had some natural light when I shot these.

I hope to post a revised track plan soon as well, as I have a few minor edits to make.  I'm getting excited to begin laying out the design on my tables.

Track Plan Progress for the UP Council Bluffs Sub

I continue to make progress on my UP Council Bluffs Sub track plan.  Much of what you see below is my initial ideas that have been somewhat refined from the original pencil and paper scribbles.  I think I have a good mix of industries that will allow for a good mix of rollingstock.  The I-80 bridge that you see on both sections is intended to help hide the seam between benchwork sections, and create a natural divide to give the layout the illusion of greater space and size.  I decided to set it at an angle to break up the straight lines of the 16' table length.  I have drawn in a second highway overpass on the far right of the track plan which represents HWY 92.  I don't know if I will keep this.  My reasoning for this bridge is to help "hide" the end of the layout, but allowing for future layout expansion if desired.

The yard area is still developing, but I intend to add a handful of tracks in a ladder configuration, plus a fueling track and maintenance shed if I have room.  Although the yard design is being inspired by the IAIS yard, it will likely be a Union Pacific yard, with the IAIS having intermodal business only.  This will still allow me to have some IAIS diesel power in the yard if I desire.

The left 8' section is also continuing to develop.  I still have some space towards the front of the table that is unaccounted for.  Some current ideas include a scrap yard, tank farm w/ loading platform, or perhaps swapping the concrete plant with a warehouse for the collection of boxcars that I currently have, which would put the concrete plant on the left front.  The lumber yard space has been reserved but lacks any building detail at this time.

The plan is subject to change, but I am liking what I have so far.  The various sidings seem to flow well, and allow for adequate space for a pair of locomotives and at least a couple of cars.  I placed a run-around track in the middle of the plan for optimal operability.  As part of a larger operation or a continuous loop, the mainline would handle run-through traffic.

Please let me know what you think.

The Time Has Come - A New Layout in the Making

It has been well over a year since I called the Marias Pass "done", put the finishing touches on my article series photos and content, and mailed it off to Seattle.  I have had lots of ideas floating in my head since then about what the next layout project would look like.  A trip this summer inspired me to consider a midwest theme somewhere in central and western Nebraska.  Then, while doing some train chasing this year, I actually found a lot of potential right in my backyard.  I have wanted to build a small diorama of a lumber facility to feature my lumber loads and centerbeams, and while pursuing that interest, discovered multiple lumber yards in and around Omaha that receive material by centerbeam flatcar.  That pursuit eventually led to more discoveries of local industries, and an idea to build a switching layout.

A switching layout?  That's right.  My previous layouts have all been primarily focused on scenery and replicating the flavor of a specific region.  Focusing further on specific industrial areas is something that I have not yet tried.  Staying true to my desire to capture at least a flavor of an actual location, I survey the area using Google maps, and then make personal appearances at locations to capture my own photos.

So how far am I right now?  A recent trip to Lowes for a home project offered the opportunity to add two sheets of plywood to the load.  So I have my benchwork material, and am getting an itch to start soon.  As far as the track design, I have good ideas of what I want, and am working on determining my industries and the general footprint for each.  I still have a lot of planning work to do, but am motivated to keep making progress.

Below is a set of photos that tells at least a portion of the story of my new layout design and concept.  The name, location, and individual industries will be loosely based on those found in and around the Omaha, Fremont, and Council Bluffs areas.  The layout will feature Union Pacific, but will have a lot of Iowa Interstate influence.  Council Bluffs sees a lot of other railroad traffic, which provides some interesting possibilities: KCS, CN, BNSF, NS, CSX, etc.  More photos to come as I capture more of the locations that will potentially make a place on the new layout.

I have driven past this plastic manufacturing building for years, taking grain to the elevator, and decided that a plastic pellet receiving track and tank storage would make a nice model.  A pikestuff building and some PVC tanks should make for a fairly simple project.

This is a cement batch facility in Fremont.  Again, a fairly simple industry to model in N scale.  A pikestuff building or corrugated styrene, some holding tanks, conveyer, and cement trucks would complete the scene.

A tank loading/unloading facility will probably be on the short list for the new switching layout.  It could either be a solvent distributor, or something larger for petroleum products.

Grain elevators are plentiful in this area, and I plan to model at least 1, maybe two if I have space.  Here is ADM in Fremont.  They process soybeans, so this would offer a space for covered hoppers as well as tank cars hauling away the soybean oil.

Both UP and BNSF have autorack unloading ramps in Omaha.  I have a nice collection of Red Caboose autoracks and would like to make use of them.  

A place to feature my lumber loads is at the top of the list.  I plan to have ample space for centerbeam flatcars, and lots of wrapped lumber bundles.  

A small engine facility next to a small yard will likely find a spot on the layout.  I am thinking about a building such as this one in the UP yard at Council Bluffs.

 Here is a nice view of the UP yard, with the Omaha skyline on the horizon.  Making my own backdrop using photos is something I want to try with this layout.

 Here is another shot of the Omaha skyline, looking west over the UP yard.

Now we are getting to some good stuff.  The Iowa Interstate railroad has a yard and intermodal facility in Council Bluffs.  N scale offers so many great models of well cars, containers, and handling equipment, and I wanted a small intermodal yard to feature the piggy packers that I recently purchased  from Wheels of Time. This yard is a smaller operation, making it an ideal prototype.  A grain elevator or two will also look right at home next to this facility.

 

Here is the entrance to the intermodal yard.

This facility uses quite a variety of container cranes.  They have this piggy packer, and a few large forklift style machines.  

Here's yet another style of container handler, with a telescoping arm.  Oh the possibilities.

The IAIS has a small engine facility, which is about the right size for a switching layout.

 Here is one last photo of the IAIS yard.