Shelf layout as baggage

[daniel_leavitt2000]

Our house in Thailand should be ready in November, and I would like to add a small shelf layout. Since Model trains (and especially N scale 1950's era B&M) are fairly scarce there, I will need to bring everything from home. This means that I will need to build a shelf layout that will fit and withstand being in checked baggage through three transfers and 15,000 route miles.

So here are some basic rules:

1. I can not replace anything model related over there. Wire, electronics some construction materials will be available, but basic model supplies can not be purchased. All of this will need to be imported.

2. I will not have time to build the layout from scratch over there. That means I need to bring a pre-made or knockdown kit that can fully assemble in a few hours at most.

3. Weight is a major factor. Layout in the luggage will need to be under 25 pounds. Also layout must be able to withstand depressurization and -80* temperatures. (Its apparently a thing that some overseas carriers don't bother to heat the cargo hold if they are not transporting animals.

4. Layout will need to measure in metrics - 1 to 1.5 meters long, but fit within a standard 28" large format luggage. 20-25cm wide.

5. Tools and wires - how do I transport these without looking like a terrorist? My main issue is that the TSA will break everything during a rummage inspection. I do have people on the Thai side to help me through customs over there.

6. Trackplan? Materials? Any ideas? We will be keeping it to Atlas C55 for track. Motive power will be a Bachmann 2-8-0, an MP 4-4-0, and possibly a 44 tonner or SW1. Timeframe will be 1950-1956. I would like to stick with steam and an urban format.

7. What about rolling stock? I have none for this time period.

[thomasjmdavis]

I had 2 or 3 ideas, but frankly, I don't know enough about foam materials (even a very small wood based layout was going to be difficult in a 25 lb weight limit) to make a recommendation.  It would strike me that anything containing air bubbles might be "challenged" by the low pressure at 37,000 feet, but I honestly don't know.   Whatever you do, you should document it and send to NASA- the International Space Station needs trains.

[Philip H]

My initial reaction is to build a Gatorfoam layout in sections. Think T Trak size. I'm sure the foam itself will survive the commute and the glue you use should as well once cured.

[Ed Kapuscinski]

This is a fascinating problem to solve!

I don't have thoughts yet, but I'm looking forward to the discussion.

[davefoxx]

My initial reaction is to build a Gatorfoam layout in sections. Think T Trak size. I'm sure the foam itself will survive the commute and the glue you use should as well once cured.

What will happen with the foam at 35,000+ feet?  Aren't there air pockets or cells in foam?

DFF

[Sokramiketes]

FedEx 

[Scottl]

I would avoid wood or any natural product to avoid issues with USDA and their Thai equivalent.  My first thought was a Peli case, and a gun style might give you some useful dimensions to work with. 

[TLOC]

I have traveled all over with my golf clubs. Maybe check with the airline and find out how much it is to have a golf case shipped. Have all the parts broken down within the case and assemble over there. You want one of the solid cases, I would think you can find them on Craig's list used or reasonable new at a Golf warehouse site.

Can't wait to see what works for you.

Tom

[Ed Kapuscinski]

I think we're approaching this all wrong.

I think the benchwork should be built there. That solves lots of shipping issues, and I'm betting the raw materials (plywood, hardware, etc...) are probably cheaper there too (as a nice bonus). How much time will you have while there? Enough to build a layout? But... are you actually going to want to spend time there inside doing that?

I'm assuming yes, though, so, lets think about stuff that won't be available....

• Track
• Cork Roadbed
• Paint (although, is there a scale modeling community there? if so, you can probably get the basics)
• Structures
• Details
• Specialized Tools
• Rolling stock
• Scenery materials

[davefoxx]

Ed,

You missed this in Daniel's post:

2. I will not have time to build the layout from scratch over there. That means I need to bring a pre-made or knockdown kit that can fully assemble in a few hours at most.

Now, that's a problem.  He wants to ship a mostly complete layout.

DFF

[Scottl]

This is what I would do- with a foam board base you could have a rock-solid, airplane approved case and there would be room for a decent layout in it.

http://www.pelican.com/us/en/product/watertight-protector-hard-cases/large-case/long-case/1750/

[basementcalling]

Gator foam would be my first choice for benchwork.

I remember back in the late 80s someone wrote an article describing an NTRAK layout he built to qualify as carry on luggage for the airlines. That determination was based on 3 measurements being below a certain total number, but those details have obviously changed in the almost 30 years since the article was published.

I think you are likely to have to do major repairs on almost anything you build and have shipped. I wouldn't expect scenic details or even track to necessarily come out damage free.  Will you be so far in the jungle you can't order from Japan and buy Kato UniTrak that way? Buildings and such would be much easier to ship in boxes in kit form, though I can see the lack of a hobby or craft store in Thailand being a deterrent to getting paints and glues and such.

One final question. Would you be better off focusing on something like weathering cars instead of layout construction? You will have to ship the layout BACK to the states if you plan to keep it. I can see it being far easier to ship a box or two of engines and cars with chalks and paints over and back than a whole layout.

[daniel_leavitt2000]

Ok to clear up a few things:

I rather not spend several hundred dollars for a pelican case. I plan on using an old 28" case:

I can ruin it if I want to.

I do not want to model over there, just run a train or two. I would like a switching puzzle style shelf layout where it would take 15-20 minutes to run sort and position the train.

This will be a detailed layout, so no unitrack.

Local benchwork is a non-starter. I will have no tools to build it. I also imagine I would need benchwork to secure the scenery during transit. As I said, this will need to be an easy build kit. I also think Gatorboard is not nearly tough enough for three international flights and a regional jumper.


Initial ideas:
Take luggage and remove lining, internal pockets and anything that is not structural or serves to protect contents. Create a hard box using thin plywood inside case. Bold shelf units directly inside this plywood box. Add aluminum stiffeners everywhere.

Basic scenery, track, ballast and foundations would be built on the shelves prior to shipping. Buildings, bridges, trees, signage and vehicles would be added after the fact. These can be stored in the hollow section of the benchwork well wrapped and secure.

Looks like the smallest jet we are using will be a 737, so no depressurization problems, but extreme changes in temperature are a given (-60 in air to 95 on ground).

I am looking at very thin plywood - 1/8" or less for building material, though aluminum, PVC/styrene and other sheet materials could work. One of the more random ideas I had was a fiberglass casting that would combine the benchwork, switch platforms, land contours, sub roadbed, streets and foundations into one part. Sure it would feel a bit like a Hot Wheels push train set, but properly scenic, it should look normal.

[Specter3]

I agree with someone else who said forget wood. Gut the case, line it plastic you bought in a 4x8 sheet and then foam, like a gun case. Layout is sheet aluminum with L pieces at edge for stiffness. Two pieces that join in middle for a 50 inch long by 12-18 inch wide layout. Buildings travel in separate case or along  the edge if weight in this one allows. Drop them on Ntrak style when you get there.

[Lemosteam]

1) Bring the base layout in the suitcase
2) ship everything on the layout separately timed to a day or two after your arrival
3) use 1/2" plywood with a 1/8" thick centered aluminum spline to assemble/disassemble, with over-center clasps on the underside to keep the the pieces together when assembled on a tabletop.
3a) build the layout in one piece
4) small square blocks underneath to space the three panels for the track and building foundations within the suitcase thickness (allowing for foam above and below them and string to tie them to one another when stacked
5)design panels 1" smaller that the inside walls of the suitcase for 1.5" closed cell foam inserts (.5" compression
6)1" foam on top, close the suitcase