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Re: The Bridges at Saltash

Posted: Fri Jan 31, 2020 7:09 pm
by kennyh
Looks brilliant Doug, is that the wall foam you mentioned to me by the way? 2"? If so it really does do the job. Great work!

Re: The Bridges at Saltash

Posted: Fri Jan 31, 2020 9:02 pm
by dkightley
That's the stuff! Dead easy to work with...it cuts with anything from a scalpel to a hand-held hacksaw blade, sands using anything that's rough!...and glues together with evo-stick.

The only down side is the mess you get when sanding, etc! But a vacuum cleaner works quickly to clear up.

Here's what I use: https://www.diy.com/departments/rectice ... 296_BQ.prd

Don't forget to let the board sit for a couple of weeks once you peel the aluminium film off each side. Try peeling off one side and look at it half an hour later...it'll be bent like a banana. Peel the second side off....and it'll flatten out....just like magic!

Re: The Bridges at Saltash

Posted: Sat Feb 01, 2020 10:21 am
by kennyh
Many thanks Doug, and also for the link. Although it is not happening in the next few weeks I will be attempting the first try at landscaping and have been looking at the options on youtube.

I'd seen the spray foam method which I'd already thought of to be honest but with the scale of T I think it's overkill.

I then saw a bloke using scrunched up paper and covering with Modroc, now that looked effective and mess free.

However this 2" foam board looks to be a winner, and at 2 inches in this scale it produces all the height you'll need unless the diorama is set in the Alps. I'm asuming the "craggy" look will just come with trial and error? Many thanks again and I look forward to seeing your layout progress.

As an aside, I am now set up with my 4 x 2 board, in a snug back room I've had permission to take over :mrgreen: Just filling in all the countersinks where I screwed it together and waiting to sand it down for action.

A bit of a hitch with my order though, the rolling stock I ordered was not in stock but should be here Monday, then the whole order will be sent out.......I'll have a 3 month play with it then whilst the dark nights are with us then continue next winter.

Just need to get my hands on it now and see how it all works. Again Doug thanks and excellent work!!

Re: The Bridges at Saltash

Posted: Sat Feb 01, 2020 12:58 pm
by dkightley
Its 1st February.....and I think its time for a recap of where I am with things. I thought I'd done this before....but can't find a post. For reference over the next few months, I'm documenting progress on the layout in a little more detail so I can see how things are progressing......

Layout boards:
All boards made and jointing methods finished.
Backdrop boards (5 off) made and most theatre hinges fitted. Boards yet to have cut-outs done for track & Tamar Bridge; boards to be surfaced with cotton sheet and image applied using tee-shirt iron-on transfers ( already bought).
Some lights already obtained. More needed & quick-release fittings needed. Lights to be powered from as few power supplies as possible.
Both left & right front covers made & painted.
Shelf for PC yet to be made (posts already printed).

Trackwork:
All track laid and joints made. Power connections all made & wires to power boxes done.
Saltash point installed and initial set-up done. Power switching board for pointwork built and tested.
Flexi-traverser built and initial set-up complete. Some more work on ensuring free-running needed.
Track not yet tested.....to progress at an appropriate time. Clean track, check points, etc, & test run train.

Electrics & Automation:
All system boxes commissioned, & wiring loom made up.
All sensors commissioned & tested okay. All trigger correct LMRI sensors
All TOTIs (train on track indicators) function tested & trigger correct JMRI sensors.
JMRI throttle control script created & simulation tested.
Train blocks identified & reference info documented for scripts. One script (shuffle up/down Tamar branch from Trav1) written and tested under simulation.

Scenery:
Foam scenery shaped to rough shape and glued down.
Road sections defined and detail on a couple almost completed. Next step is to start fitting road sections to foam.
All identified buildings have been designed and printed. Two require splitting over layout joint and reprinting.
Start made on painting buildings, etc. Appx six completed to date, plus Saltash side boatyard.

Royal Albert Bridge:
All viaducts completed and painted.
Saltash side lower piers fitted to board and upper viaduct (removable section) assembled.
Plymouth side assembled & fixed to board.
Bridge arches assembled and 90% painted. Both end piers are still to be final fitted.

Tamar Bridge:
All main bridge components printed. Sections require checking & holes drilling for fittings, etc.
Under-deck girderwork sections printed. All require cleaning & checking for fit, etc.
Both drive sections have most parts printed. Parts need support removed, checking & cleaning up.
Main frame sections and roadways needed reprinting; need to establish which have been done & what printing is left to do.
157 vehicle drive chain sections printed...another 600 needed.
Suspension cable need building. Need to identify what cable/wire to use.
Transport board to be established....probably using back section of layout board with lightweight cover.

Rolling stock:
Class 800/3 shells printed & decals designed. Power units purchased. DCC chips to fit.
Class 150 DMU shells printed & decals designed & applied. Power units purchased. DCC chip fitted to one unit.
Class 170....two shells require printing & decals to design. To use existing 170 power units.
To decide on freight loco & wagons at a later stage. Aim is to have a minimum of four trains set up and running under automation control.....

Mics items, set:
Appx 140 cars & vans printed. More cars, vans & lorries/buses needed.
Already have a number of people...to identify more as required.
Transport rig for layout and track sections, etc to be determined.
Trailer to be serviced/refurbished by JB. Cover needed.


I think the next update will be in the form of a to-do list, as opposed to a mix of what's done and what's left to do.

Re: The Bridges at Saltash

Posted: Wed Feb 05, 2020 7:57 pm
by dkightley
I've started "fitting" the building into the scenery. As most of the buildings are on a slope, I've made them with flat undersides..and then sculpturing out foam so the sit level.

Here's a few (slightly hazy...didn't realize I had dust on the camera lens!!) shots:
IMG_4072_red.JPG
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IMG_4074_red.JPG
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IMG_4086_red.JPG
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btw Its not an early Easter chick in the background of the top shot. Its just a curly bit of paper!!

Re: The Bridges at Saltash

Posted: Mon Feb 10, 2020 12:51 am
by dkightley
The bulk of my progress since the last post has been on Tamar Bridge.

I've designed and printed a drilling jig so that holes for the suspension cables can be drilled in the deck sections I've also cleaned the under-deck girderwork sections of all the remnants of support and printing "hair" so they all fit together nicely!

I decided to re-create the drive mechanism chassis at both ends. I've printed most of the chassis for one end...a couple of parts left to print, then I need to flip the designs to print the same for the other end.

I have around 350 chain links printed now....I keep setting one printer off whenever I can to print a batch of 25. And I think I've sorted out the suspension cables...16 swg piano wire with 20 swg hangers fixing to the main cable by either soldering or glueing. Not sure which at the moment. And I've confirmed the way of transporting the bridge....the rear section of layout board turned over forms a shallow tray that almost fits the whole bridge/drive mechanisms.....the outermost legs of the chassis will fit just outside the tray, leaving the rest sitting nicely on the underside of the board top! And with it already being a "tray", there's a level of protection there.

Finally, here's a photo of a spread of parts that form the bridge:
IMG_4091_red.JPG
IMG_4091_red.JPG (115.66 KiB) Viewed 2157 times
At the front is the newly printed chassis with the yet to be reprinted chain distributer, then the ten deck sections and eleven under-deck girder sections; they fit together staggered for rigidity. At the far end is a complete old-design drive chassis. Most of it needs reprinting since I changed the design of the basic chassis! And alongside is the upturned rear layout board which will form the transport frame.

Re: The Bridges at Saltash

Posted: Thu Feb 20, 2020 11:09 am
by dkightley
The past couple of weeks have been quite strange....

Things started badly with the death of a friend and fellow volunteer at Crich...and the resulting fallout of helping to deal with things that needed doing that he was involved in. I ended up having to spend a couple of days sorting out data for the tram crew roster system, and a day creating a new page on the roster system to help the yet-to-be-recruited new roster clerk.

I've also just done a 3D printing demo at the Syston MRC show, which went ahead despite the nearby brook overflowing overnight and roads in the area having to be closed!! I've also been persuaded to do a talk this Saturday evening at Crich on my layouts...and I have another 3D printing demo session at a local railway club on Sunday. All the preparations, etc have taken time....

On the layout, I've made a minor design change to the Tamar bridge vehicle drive system....and I've reprinted most of the parts of both of the run-around chassis. The final two prints are 50 hour plus prints, and the first is about 90% done as I type. I've also done a first fitting of the road bridge to the layout; I've cut out the edges of the scenry to accommodate the front of the run-around chassis at both sides. And not all that much else, I'm afraid...…

Apart from a minor step backwards!! Cleaning up bits of hacked & sanded off scenery foam there was a "ratt-tat-tattle" of something vanishing up the vacuum cleaner pipework. I think it was a corner of a building that fits at the edge of the layout....but a headcount of buildings will confirm when I get the chance. It's only a half-hour job to reprint!!! Good job it wasn't painted....

Re: The Bridges at Saltash

Posted: Wed Feb 26, 2020 10:56 pm
by dkightley
Finally a bit of visible progress.....

Here's a shot of a very untidy layout with the suspension bridge placed when I marked out for fitting the ends into the scenery:
IMG_4098_red.jpg
IMG_4098_red.jpg (142.49 KiB) Viewed 1821 times
And a couple of shots of progress getting the scenery in Saltash close to final shape with a few more buildings fitted in their holes:
IMG_4109_red.JPG
IMG_4109_red.JPG (117.84 KiB) Viewed 1821 times
]
IMG_4105_red.JPG
IMG_4105_red.JPG (135.34 KiB) Viewed 1821 times

You can see where one of the roads runs uphill from a flat area at the water's edge and goes under the first viaduct section....go under the bridge and turn left, and you're at the station!

Re: The Bridges at Saltash

Posted: Thu Feb 27, 2020 1:57 pm
by kennyh
Superb!!

Re: The Bridges at Saltash

Posted: Fri Feb 28, 2020 10:46 pm
by dkightley
Finally managed to get a day's work on the layout...and its something I really like doing. Only problem is that my back has stopped talking to me. It's shouting!! Never mind...

And here's a shot of today's progress:
IMG_4113_red.JPG
IMG_4113_red.JPG (102.23 KiB) Viewed 1725 times
And here's Google's version of the view.....
GoogleVerOf_4113.JPG
GoogleVerOf_4113.JPG (126.92 KiB) Viewed 1725 times
All the buildings you can see in the shot have been trial fitted into their location and the scenery surface shaped ready for fitting the road surfaces and finishing off!

Re: The Bridges at Saltash

Posted: Fri Feb 28, 2020 11:30 pm
by dkightley
By the time I post this it'll be as near as damn it 1st March and 167 days left before the layout needs to be ready....and a recap of where I am with things is needed. Anything in black was on the last list and is not done. Anything in green had already been done or has been done since the last list ( and will disappear from the list next time), and anything in red is a new item to do.......

Layout boards:
All boards made and jointing methods finished.
Backdrop boards (5 off) made and most theatre hinges fitted. Boards yet to have cut-outs done for track & Tamar Bridge; boards to be surfaced with cotton sheet and image applied using tee-shirt iron-on transfers ( already bought).
Some lights already obtained. More needed & quick-release fittings needed. Lights to be powered from as few power supplies as possible.
Both left & right front covers made & painted.
Shelf for PC yet to be made (posts already printed).

Trackwork:
All track laid and joints made. Power connections all made & wires to power boxes done.
Saltash point installed and initial set-up done. Power switching board for pointwork built and tested.
Flexi-traverser built and initial set-up complete. Some more work on ensuring free-running needed. To fit stop screws to traverser & springy links on servos.
Track not yet tested.....to progress at an appropriate time. Clean track, check points, etc, & test run train.

Electrics & Automation:
All system boxes commissioned, & wiring loom made up.
All sensors commissioned & tested okay. All trigger correct LMRI sensors
All TOTIs (train on track indicators) function tested & trigger correct JMRI sensors.
JMRI throttle control script created & simulation tested.
Train blocks identified & reference info documented for scripts. One script (shuffle up/down Tamar branch from Trav1) written and tested under simulation.
Existing script requires testing. Additional scripts to determine and write/test.

Scenery:
Foam scenery shaped to rough shape and glued down.
Road sections defined and detail on a couple almost completed. Next step is to start fitting road sections to foam.
All identified buildings have been designed and printed. Two require splitting over layout joint and reprinting. Remaining building yet to paint.
Start made on painting buildings, etc. Appx six completed to date, plus Saltash side boatyard.
Number of trees required to be estimated and trees made & fitted
Beaches on both sides to be laid down.
Water surface to be painted.
Complete fitting of buildings into scenery foam.


Royal Albert Bridge:
All viaducts completed and painted.
Saltash side lower piers fitted to board and upper viaduct (removable section) assembled.
Plymouth side assembled & fixed to board.
Bridge arches assembled and 90% painted. Both end piers are still to be final fitted.
Small retaining piece on Plymouth end pier requires refitting.

Tamar Bridge:
All main bridge components printed. Sections require checking & holes drilling for fittings, etc.
Under-deck girderwork sections printed. All require cleaning & checking for fit, etc.
Both drive sections have most parts printed. Parts need support removed, checking & cleaning up.
Main frame sections and roadways needed reprinting; need to establish which have been done & what printing is left to do.
157 vehicle drive chain sections printed...another 600 needed.
Suspension cable need building. Need to identify what cable/wire to use.
Transport board to be established....probably using back section of layout board with lightweight cover.
Reinforcement to deck to girder frames required.

Rolling stock:
Class 800/3 shells printed & decals designed. Power units purchased. DCC chips to fit.
Class 150 DMU shells printed & decals designed & applied. Power units purchased. DCC chip fitted to one unit.
Class 170....two shells require printing & decals to design. To use existing 170 power units.
To decide on freight loco & wagons at a later stage. Aim is to have a minimum of four trains set up and running under automation control.....

Mics items, set:
Appx 140 cars & vans printed. More cars, vans & lorries/buses needed.
Already have a number of people...to identify more as required.
Transport rig for layout and track sections, etc to be determined.
Trailer to be serviced/refurbished by JB. Cover needed.

Re: The Bridges at Saltash

Posted: Sun Mar 15, 2020 3:35 pm
by dkightley
After a heavy week or two working on Tax data for the Tramway Museum Society, I've finally managed to get a bit more building painting done:
IMG_4117_red.JPG
IMG_4117_red.JPG (125.83 KiB) Viewed 1841 times
Looking more like the real thing...…

And to release my laptop from train running duties I've invested in a little bit of technology,,,,,a Raspberry Pi. It will run the Linux version of JMRI so should work quite nicely. Just under a hundred quid for the Pi and its power supply, etc, and a monitor....less than a third of the price of a new laptop!.

Re: The Bridges at Saltash

Posted: Mon Mar 16, 2020 4:20 pm
by mattd10
This is all coming along great! Really pushing the boundaries and showing what can be done in T!

Re: The Bridges at Saltash

Posted: Tue Mar 17, 2020 12:23 am
by dkightley
This is just one 3D printed building....a terrace of ten town houses....complete with front gardens! There are back yards on the other side...and a few extensions. Its been a long day painting...….
IMG_4120_red.JPG
IMG_4120_red.JPG (83.86 KiB) Viewed 1804 times
….but worth it! ;)

Re: The Bridges at Saltash

Posted: Fri Apr 17, 2020 4:46 pm
by dkightley
Its been a month since my last update...but I have been getting on with things....

I've moved on with the design of the construction of the suspension bridge and the car tracks, both of which are progressing okay. But the big landmark (pun not intended....but left in!) is that I have completed painting all of the buildings on the West (Saltash) side of the river.....just under 130 buildings altogether.

Here's a few shots of buildings in almost their final positions....
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IMG_4143_red.JPG
There's not so many on the East (Plymouth) side....just under 50. I'll probably start on them tomorrow.

Re: The Bridges at Saltash

Posted: Sun Apr 19, 2020 9:04 pm
by dkightley
This evening's work:
IMG_4155_red.JPG
IMG_4155_red.JPG (63.74 KiB) Viewed 1612 times
Time for a rest, I think.....

Re: The Bridges at Saltash

Posted: Tue May 05, 2020 4:10 pm
by dkightley
I like landmarks!!!

Particularly the ones that you reach!

And the one I've just reached is completion of painting of all the buildings and other 3d-printed scenery sections for the layout! All 182 of them!!!

And here's a shot of most of them...minus some of the small bits that I have bagged so I don't lose them!:
IMG_4157_red.JPG
IMG_4157_red.JPG (146.6 KiB) Viewed 1535 times
Now to get stuck into finishing off and fitting the road sections...and gluing down some buildings....

Re: The Bridges at Saltash

Posted: Tue May 05, 2020 5:41 pm
by martink
And I was patting myself on the back for completing the dozen or so for mine... That is some seriously impressive work, and I think a lot of us are eagerly waiting to see the whole thing in its completed form. Or even just with the main elements in place and everything up and running.

Re: The Bridges at Saltash

Posted: Tue May 05, 2020 6:11 pm
by dkightley
Continuing the countdown to a deadline that may or may not exist with the current Covid-19 situation, I now have 102 days left before the layout's first possible outing. having finished painting the buildings, I think its time to review the "To do" list.

The list I've shown previously have been a recent progress and what to do next list...and not an absolute "To do" list. Hopefully this list includes what I know actually needs doing:

Layout boards:
Backboards yet to have cut-outs done for track & Tamar Bridge; boards to be surfaced with cotton sheet and image applied using tee-shirt iron-on transfers ( already bought).
More lights needed & quick-release fittings needed. Lights to be powered from as few power supplies as possible.
Shelf for PC/Pi yet to be made (posts already printed).

Trackwork:
Some more work on ensuring free-running of traverser operation needed. To fit stop to traverser.
Track not yet tested.....to progress at an appropriate time. Clean track, check points, etc, & test run train.

Electrics & Automation:
Existing script requires testing. Additional scripts to determine and write/test.
Raspberry Pi to set up with JRMI & test operation capabilities. (Fallback to laptop if necessary.

Scenery:
Complete fitting and glue down road sections to foam.
Complete fitting of buildings into scenery foam. Plymouth side requires large amount of foam removing.
Number of trees required to be estimated and trees made & fitted
Beaches on both sides to be laid down.
Water surface to be painted.


Royal Albert Bridge:
Complete painting of bridge girderwiork
Both end piers are still to be final fitted.
Small retaining piece on Plymouth end pier requires refitting.

Tamar Bridge:
Spring wire for cables needs cutting to length and fitting.
Drop wires require measuring, bending & soldering to main cable.
A number of drive chain links yet sections printed...another 600 needed.
Commissioning of drive track to be completed…initially with drive units back-to-back, then with bridge deck included.
Transport board to be established....probably using back section of layout board with lightweight cover.
Reinforcement to deck to girder frames may be needed.

Rolling stock:
DCC chips to fit to 800/3 set.
Class 150 DMU - DCC chip to fit to one unit.
Class 170....two shells require printing & decals to design. To use existing 170 power units.
To decide on freight loco & wagons at a later stage. Aim is to have a minimum of four trains set up and running under automation control.....

Mics items, set:
Appx 140 cars & vans printed. More cars, vans & lorries/buses needed. All require painting!
Already have a number of people...to identify more as required.
Transport rig for layout and track sections, etc to be determined.
Trailer to be serviced/refurbished by JB. Cover needed.

Re: The Bridges at Saltash

Posted: Thu May 07, 2020 7:51 pm
by dkightley
Today's progress is hardly visible....but I have the first three road sections fixed down to the scenery.
IMG_4160_red.JPG
IMG_4160_red.JPG (122.4 KiB) Viewed 1473 times
I just need to wait for the glue to set and I can knife through the overlapped joins between the sections, and glue them down and seal the ends to stop ingress of moisture...which would make the printer ink smudge! You can see the overlaps showing as small gaps.