Wednesday 28th June 2023

Worklist:

Footpath.

Factory cladding and roofing.

Geoff started the session by completing the footpath 'topping' in front of the cottages. This comprised a diluted PVA basecoat and a sprinkled mix of fine grits and powders.

We do get a bit untidy sometimes!

Stephen first trimmed-off the excess cladding panels along the roof edge, which is always a pleasing task - unveiling the final gable. He then assembled the remaining bulk of the cladding panels and glued them in place. The panels around the link building junction were cut out and fettled to shape, then glued in place. Finally, he fabricated a gutter in plasticard, to replace the cardboard mock-up unit. The new gutter allowed the adjacent cladding panels to be trimmed to suit and they too were glued in place. The full outlet box will be formed in due course.  

Geoff 3D printed some ridge sections. Although representing galvanised steel sheet, they are quite thick as looking from above, they have to 'appear' to be covering the top of the roof sheets. Gable plates/finials will hopefully disguise the arrangement on the ends.

Over lunch, we spent some time researching fascia boards for the corrugated roofs. Timber planks and metal pressings were found, but Geoff fancied distressed timber, so he produced some from 1/32" basswood sheet left-over from the wagon making.

The overall appearance looks more real as the details are applied.

Wednesday 21st June 2023

Worklist:

Factory cladding.

Scenery.

A Windows update had messed up Geoff's CAD program, which needlessly had to be upgraded/reinstalled - time, hassle and money....

Geoff first modified the ridge strip produced last week, changing the design to make it easier to print. However, the units weren't printing properly. It was eventually found that a new batch of resin had different characteristics, that required changes to the print settings stored in each drawing. This will require all previously stored drawing files to be modified and re-saved before they can be reprinted. 

The end of the ridge is too chunky, but a gable end feature will be produced to cover the exposed ends. Note the curved black panel. This is from a batch left uncured to remain flexible (as an experiment for easier gluing), which seems to be working. We'll know for sure when we leave it in sun to harden fully.

Meanwhile, Stephen pressed on with the cladding for the main factory building, working out a new panel arrangement using those produced already.  Once agreed, he started gluing them in place. A shortage of one size meant gaps had to be temporarily filled with unglued units, until the printer was back in full production.

With the printer finally in full-flow, Geoff returned to the scenery. He vacuumed off the loose scatter material 'weeds' on the track, which looked good. 

He moved on to a corner in some Slaters fencing that was proving difficult to control. Using copper wire, glue and shrubs it was finally tamed.

It has been interesting to see the subtle differences in the two buildings develop, based on the different sizes - quite prototypical.

Windows were discussed, together with rainwater pipes, vents and ventilation units etc. All to be agreed in due course.

Wednesday 14th June 2023

The day started with a discussion about an offer from the organisers of the Model Railway Show at the NEC, for Worton Court to attend their show. However, their preference was for the full 6-board layout, which was great, but we had to ensure that we could get it ready. We started to discuss the work required to not only finish the two new boards, but also how the existing exhibition equipment could be extended -  extra trestles, lighting rigs, drapes, transportation, operating personnel etc. The list got bigger, but hopefully, not beyond our capabilities. More anon.....

Today's worklist:

Continue cladding the factory buildings.

Turn back the time on the trackwork.

Stephen carried on with the hidden facade of the front building and managed to complete the link building as well.

He then turned to the roof. Two of our standard lengths spanned just short of the apex. To reach the ridge, a modified top panel could be made and an overlaying ridge section produced.  However, as our standard 'overlaid' panels actually abut each other, a ridge unit will be made that will abut the upper sheets. After some Google image searches, the ridge was agreed, designed and sized. Geoff will draw and print a sample for next week.

Finally, the window apertures were cut out. The double foamboard core doesn't cut smoothly and so the 3D printed windows will have the window reveals incorporated.

Geoff had been looking at old videos of the the early days of the Talyllyn railway, in particular, the overgrown state of the track at the time of its opening, and he decided to replicate the same feel. A selected mix of flock and foam were glued along and beside the track, on a bed of diluted PVA.

The effect was superb any misgivings were laid aside. On a sample area, an overcoat of a lightly sprayed glue or hairspray will be tested to prevent the foliage lifting and catching in the under gear.

Geoff also produced another mix of powders and fine grit for the cottage footpath. Laid on a bed of PVA, we'll see how it actually looks once the excess is hoovered off next week.

Another issue discussed was the backscene - the 6mm vertical white-painted MDF board at the rear. On Worton Court station, it is at a height that allows operators to reach the track. Towards the bridge/tunnel end, it rises up to a higher level, where no track access was required. On the new boards, the station level would be required through the factory area. For the cottages and engine shed area, a level between the two could be accommodated, but not the high level. After experimentation, a suitable height was agreed for the first 500mm which will require the WC back board to be reshaped accordingly. 

Our panel of rubberised horsehair had arrived. We will start adding a few shrubs in due course!

7th June 2023

Worklist:

More corrugated iron....

We just picked up where we left last week - Geoff printing panels and Stephen sticking them down. The first difference was that Geoff had a new batch of resin, which was almost black. The second was that he decided not to UV cure the new panels, leaving them slightly flexible so they remained flat. Once securely glued to the foamboard substructure, they would then be cured with UV light - possibly left in the sun. 

A new panel was required for the window heads.

We then looked at the flying link structure. Corrugated sheet had been stuck on one side, with two small windows, similar to the Westinghouse units. Printed panels were now applied to the reverse side and a single window will be formed instead. 

The track-side facade will be invisible to all but long-necked viewers, but not to operators, so it received a layer of slightly imperfect cladding panels.

Plenty more wall panels to go....  and then we'll have to tackle the roofs, windows, gutters/downpipes, external services....

We also had a look at the new areas of landscaping and decided that some shrubs would be nice. The natural plant shrub substructure we'd used on the station boards was very fragile and almost all had broken up. Lamenting the 'rubberised horsehair' John had obtained from British Airways bins (packing material), we tried eBay and found some that looked the same. It should be delivered by next week.

Wednesday 31st May 2023

Worklist:

Apply corrugated iron sheets onto building shells.

The free-standing building had been selected for the first concerted effort on the factory buildings' cladding and a corner completed. More flattened sheets were laid in place to confirm the arrangement. A different contact adhesive was tried, which was more fluid and could be applied with a small flat brush. This was not only easier to apply, but also had greater adhesion.

All loose laid panels except for left hand corner.

Once the layout was confirmed, panels were applied. The final effect was somehow far more effective than the thinner sheet material used for the loading dock. Each panel seemed more realistic and distinct from the others. Maybe the almost invisible bolt detail makes the difference. We were very pleased.

The roller shutter door will be made from corrugated iron sheet.

Next - Apart from more cladding, the openings will be carefully cut out. Windows will be drawn and 3D printed, similar to the engine shed windows. The Westinghouse site buildings offer a range of pane sizes and orientation that gives both character and a free hand in design.