Just the one this time - fit the alignment pins so the layout can be accurately assembled.
There are three joints on the layout and the centre joint has pins fitted already, so just two to do. However, the centre joint does not align the track properly, so remedial work will be required.
With Laurence exploring the Dorset of his youth, with the love of his youth, Geoff and Stephen set-to with the task at hand.
The process is complicated by the necessity of drilling holes from the 'outside' i.e. there isn't room to get a drill under the board.
Laurence had made the pins and drilled out some large washers to snugly fit over the pins. The washers were then drilled and countersunk to take three fixing screws each. Plain washers, the size of the bolts used for the pins were to hand. He's the process for upgrading our 'pre-existing' boards:
- Take a rod of metal (approx 4-5mm dia.) with a point turned on the end - the pointer.
- Drill a pair of holes in one board face that will take the pointer smoothly, but not too tight.
- Assemble the boards aligning the track and tighten the board bolts.
- Tap the pointer through each hole to the other face and remove.
- Undo the bolts and separate the boards.
- Using a wood bit, form a recess to take a large, plain washer.
- Screw the washers into the middle of the recess.
- Open up the pilot holes on the other board. These will take the alignment pin screw shanks. By over-sizing them, they can be manoeuvred into exact alignment by the washers, as the boards are joined.
- Apply glue to the alignment pin screw holes and shanks. We used Gorilla glue - an expanding cyanoacrylate.
- Assemble the boards, tightening the nuts on the pin shanks. Check the track alignment at each phase.
- Leave to set.
We managed to complete both joints, which surprised us both!
Next time, we'll test the assemblies and have a look at the centre joint again. Then, we'll be able to put the layout up with ease and finish off the mine track cassette interface.
Geoff had found a 00 track ballast that was very similar to the existing ballast, so some trial track repairs can be undertaken.
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The pointer pushed through its hole. The other hole is the regular board bolt hole.
The pilot hole used as the centre for a large Forstner wood bit.
With the washer dropped into place to check the depth. These are original washers from the Cottesmore layout days - ex British Airways (we think).
A pin locator washer screwed into place.
With a pin head dropped in. With a plain washer on the screw thread, the pin will be glued into the other board face through an over-sized hole. Expanding glue with fill the void around the screw, which will be in perfect alignment (!)
