Lightweight, indestructible shelf layout ideas?

[daniel_leavitt2000]

Ok, I need help. I have a basic track plan for a 12' by 8' or 12' layout for the house in Thailand. I want to build a shelf layout that:

1. Can be transported in 1-2 large pieces of gutted luggage.
2. Light weight enough to be under the 50 pound limit for international travel.
3. Can withstand a 9000 mile trip with 3-4 plane changes.
4. Track wont warp or buckle with extreme temperature and humidity changes. This would include in-flight temperatures of about -45 and on the ground temps in the mid 90's with 100% humidity.

Since I will only be there a few weeks a year, building the entire layout on location is not really viable. The other issue is obtaining correct construction materials (dimensional lumber isn't really a thing there). What I would like to do is have a series of modules that bolt together to make the shelf. Track and wiring would be constructed here, while scenery would be completed there. Everything - foam insulation, trees, ballast, structures - would need to be brought with me.

Ideas?

[DKS]

While nothing is "indestructible," my inclination would be to use multiple layers (3-4) of 1/2-inch Gatorfoam bonded together with contact cement for the bases, wrapped with aluminum angle shapes for edge protection as well as sturdy module connection points/leg attachments. Gatorfoam offers more rigidity than foam insulation alone, and the aluminum frame is immune to dimensional instability. If the track was bonded to the Gatorfoam with double-sided foam tape, it should likewise be immune to temperature and humidity extremes. Although not especially economical, this approach should be quite robust. I would avoid the use of any dimensional lumber--it is heavy and prone to dimensional instability.

 

[peteski]

So this is a one-time deal jst to bring the benchwork from USA to Thailand?  Why not use one of the shipping companies, crate the benchwork and ship it?  Yes, it will cost some money, but is the shipping cost *THAT* expensive?  It could be sent ground (um, water), not air.  I don't think that the cost would be prohibitive.

One of my ex-coworkers was building a retirement house in Cape Verde and he shipped a good portion of the needed building supplies from US to Cape Verde.

[Ed Kapuscinski]

I was just thinking that aluminum shapes are gonna be your friend for benchwork. DKS is (as usual) spot on with the gatorfoam recommendation for scenery/base.

The aluminum pieces are easy enough to get at Lowes or Home Depot and are easy to work with. If you do it right you might be able to design them so that you can join them in interlocking L shapes to maximize storage volume in the luggage.

Also, DOCUMENT the crap out of this! It has magazine article written all over it.

[wm3798]

It might be easier and make your life more interesting to enjoy being in Thailand for those couple of weeks a year.

Leave the trains in your mainland house.  In the end, you'd be putting a lot of energy and effort into a problem that really doesn't need to be solved...

Unless of course, the only time you're there is at the height of monsoon season, and you can't go outside to do anything else.  And even if that's the case, I'm sure your wife would enjoy playing cards or scrabble with you, rather than you being in a train room playing with, you know, yourself...

Lee

[peteski]

It might be easier and make your life more interesting to enjoy being in Thailand for those couple of weeks a year.

Leave the trains in your mainland house.  In the end, you'd be putting a lot of energy and effort into a problem that really doesn't need to be solved...

Unless of course, the only time you're there is at the height of monsoon season, and you can't go outside to do anything else.  And even if that's the case, I'm sure your wife would enjoy playing cards or scrabble with you, rather than you being in a train room playing with, you know, yourself...

Lee

Actually that was also going to  be my earlier reply (then I changed it to what I posted).  There are plenty of portable modeling tasks which can be done without a layout handy nearby.  We have few members here who travel with a portable workshop and do their modeling in hotel rooms.  You can do some painting, weathering, decoder installs and programming, assembling structures, etc. while on the road (or during your stay in Thailand).

And maybe you could get your wife to join the fun.  Maye she would enjoy weathering or making scenery (like trees)?  Maybe even do decoder installs. Who knows?

[nuno81291]

A 12x8 around the room shelf that fits in luggage?!

Curious to see how you make out... no idea here. Sounds like the sort of layout that can be all consuming, without being restrained by a few weeks a year time frame. If it were me I would aim for a much smaller layout, even perhaps just photo diorama and practice on weathering and photos with a few good dioramas. My HO layout is about the same size and I couldn’t imagine making something so large fit in luggage. Let alone how long it takes for me at my snail pace to build and scenic. But if you can pull this off (without a divorce  ) then more power to you.

[VonRyan]

Also, DOCUMENT the crap out of this! It has magazine article written all over it.

One of my close friends had an article published in MRH about how he built his Free-Mo module while he was in Afghanistan.

I believe the article is called "Free-Mo in a Foreign Land"

[cne_craig]

Hi Daniel,

I still recommend using HDU board and building a channel shaped design for the module.  I have a few pieces at the house if you are interested in looking it over.  HDU is very stable (temp and humid) and the pieces can simply be glued (epoxy) together to make the channel shape.  I suggest the channel shape for a couple of reasons; (1) more rigid structure, nice and stiff , (2) modules can be stacked providing some clearance for the top surface.

Cheers
Craig in Stow

[Spades]

Daniel

Some validation from a total stranger offering advice on something that is none of his business.  I think Lee W's advice is perfect. 

Most countries are very strict on imported wood.  If you do decide to go ahead why not use locally sourced materials?  Avoid the hassles of transporting, TSA sniffing your luggage.  Oh, and Thailand's Customs officials.

[OldEastRR]

Lightweight, indestructible, small segmented, travel-proof, Customs-friendly, and finished size 12'x8' ..... wow.  I thought the first two requirements were tough enough to meet. But I'm pretty sure the US military could come up with the perfect answer -- for a cost of about $1B. A bunch of Unitrack set up on a locally-purchased table (or 2) used exclusively for trains (and left in Thailand) wouldn't work? Or even buy the local wooden furniture and cut it up for framing?
However, if you have a budget equal to the US armed services I guess anything is possible. 

[daniel_leavitt2000]

The layout would only be 12" X 8' or 12" X 12', not a 'round the room layout. So this would be done in 4 or 6 12" X 24" sections which would fit within 2 large pieces of luggage.

There are a few reasons for the project. Joy is usually with family and friends. I am often there doing my own thing as I can't follow the conversation. Our house is in monsoon country so there is that too. Finally, I want to find a home for my B&M steam.

And frankly, this is a big challenge. And I like the idea of overcoming a major challenge.

Oh and for a Model Railroader article. Because I haven't seen my name in print in a while.

Oh Christ Craig, I need to get those engines back to you. They have been sitting on my workbench for months. 

[nuno81291]

Your OP says 12’ x 12’ or 8’, hence the confusion. Sounds much more feasible now. Would love to see a track plan, even if a napkin sketch.

[peteski]

Yeah, the dimensions in the initial post were all in feet (not inches). 

I still say to at least try one time to just spend the time there working on locos, rolling stock or buildings (or other small items for your layout in US).

[daniel_leavitt2000]

Wow Gator is expensive! I'm guessing using several laminated 3/16" think boards in a staggered pattern would be much stronger than using just the 2" thick version. What type of glue should I use?

Here is a quick sketch of the basic layout. Nothing crazy. Just a dilapidated branch serving a few industries. The house by the brook is actually my focus. Disused, tarpaper siding, beautifully depressing.

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