Eastern New England Chapter
New Display Module Construction – Power Substation
By: Jeff Koellmer
Recently, the chapter decided to embark on a long-term effort to develop new display modules and perhaps to replace some of the older, heavier modules that were beginning to show wear and tear from constant moving. An important part of the development plan was to utilize Märklin’s new C-track that enabled improved model running over track joints. In order to ensure consistency when several modelers are involved, a Module Construction Manager was elected and standards for construction were drafted. As a relatively new member of the organization, and with little prior experience in scenic-ing, I volunteered to construct one. This article describes the step-by-step process I followed and hopes to be somewhat inspirational for others who may be considering doing the same.
My first task was to determine what “scene” my module would portray. Our new standards for consistency required only that the theme be “European”, era-less and depict the summer season. My wife, Chris, and I thought about this for a while and decided that an electrical power substation might be an interesting scene. We didn’t recollect seeing one modeled on a display before. The fact that our group’s module display would be entirely electrified with overhead catenary made this choice seem even more logical. We purchased a model kit of a European power substation, some out-buildings, vehicles and other supplies at our local hobby store. Chris began to construct the models and I got to work on the module base board.
Our Module Construction Manager fabricated the basic base board, about 1.5m x .7m in dimension, made of light-weight rigid foam sheeting over a ¼” plywood honey-comb-like frame. An irregular shape for each base board was intended to enhance viewing appeal. The base board came to me complete with special pins to ensure proper alignment with my neighboring modules, and one set of folding legs with adjustable feet to account for any uneven flooring at a train show venue. Everyone constructing a new module starts with this “stock” base board kit. The Module Construction Manger developed a basic track plan that included one through-track on my module and part of a passing siding. C-track would be affixed to the boards at ground level. I obtained the necessary track pieces and placed them on the board, traced their path onto a sheet of ¼” plywood, and then cut the piece to shape. I measured for cross members, and then fixed the plywood track base to the base board surface. I used liquid nails and a few, short drywall screws embedded in pre-drilled and countersunk holes. Knowing the dimensions of our power substation kit, we determined where they should be placed on the terrain and marked the spots accordingly. I next contacted my fellow chapter members who were constructing modules to the left and right of me. We coordinated common end contours and traded emails and post for actual templates. The templates were fixed at each end and my terrain could now be constructed. The photo below shows the original base board, track bed and the end contours attached.
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The next step in the process involved building-up the contours and providing more interesting terrain over the foam base. I chose to stack additional pieces of foam using liquid nails, and to carve their edges using an electric foam cutter and small, serrated knife. I could have constructed a hollow frame made of cardboard strips, but this technique is customarily used when access is required beneath elevated track, for instance. Since no access was required in my case, and because I wanted the additional durability of a “solid” area, I opted for the stacked foam technique. When satisfied with the end contours, I decided on contours for the front and back of my module; the only limitation being that both properly met the end contours. Using an electric jig saw, I randomly carved some interest into two pieces of “whacky wood” and attached them to the front and back fascias of my module. Whacky wood is a very flexible wood product that can follow the irregular curves of the base board without cracking and splitting. Additional layers of rigid foam were glued in place and carved until the desired contour was achieved. All four sides were given a base coat of the “standard” paint color.
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Before progressing too far on top of the base board, I needed to do a little work underneath. I stood the module on its side to expose the folding legs. They needed a mechanism to stabilize them when opened for module set-up. A small closet bolt was added to a supporting block for use when the leg was extended and seems to do the trick:
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I decided to give the legs a coat of polyurethane for added moisture protection before placing the module upright again. The terrain could again be worked. With all layers of rigid foam in place and roughly trimmed, my next step was to further smooth out the terrain and add some character. The objective was to make the terrain look as much like real earth as possible. I used plaster cloth to make gentle transitions from one layer to the next. Since the plaster cloth needs to be dunked in water and applied “soggy”, I decided to first remove the C-Track and place it aside. Wrinkles and other irregularities are difficult to avoid in this process, but I felt they added additional character anyhow.
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When all the elevated areas of my module were covered with plaster cloth, and after the cloth had “set” for several days, I applied a skim-coat of wallboard compound over the cloth with a course brush. Because most of my module would be grass-covered, I mixed a little water-based green paint in with the compound. This lessens the appearance of annoying “white spots” as the plaster gets dinged. Our chapter participates in a rigorous schedule of public train shows and the modules get a lot of “handling”. Areas where my power substation and out buildings would be placed were left uncovered by the compound during this process since I wanted a flat, stable surface to place the models.
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The next step was to add more character by including plaster rocks. My neighbor’s module was nearly complete at this time and included several rock faces. I wanted to carry his theme through to my module, again for consistency sake. Several random pieces of plaster rock were glued in place near my end contour (using ordinary white glue). After the glue dried, I surrounded the rocks with a maché-type substance to better blend with the terrain. I next coated the rocks with a paint/stain/wash solution that was as close to my neighbor’s chosen color as I could make it. I had to rely on pictures for this match-up and hoped for the best when we were matched up for real! A small out-building was glued in place for additional effect on the hill side.
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When the mold compound was dry, the process of adding authentic-looking grass, trees, buildings and other natural effects began. Chris had now completed the model, with its numerous transformers, rectifiers, cables, insulators and every other thing one could imagine related to a power substation. We mounted it to the base board, along with the other out-buildings she constructed from kits, by kit-bashing and by sheer inventiveness. A mixture of “wet water” (scenic glue) was then sprayed over the surfaces that were to be textured further. Blended turf (from Woodland Scenics) was sprinkled on to the wet surfaces. Several layers of different colors were liberally applied for effect. Brown colored materials were used for dirt paths, roadways and the like. After the initial application of materials had soaked up a little of the wet water, a second misting of glue was applied to keep it in place. All areas were allowed to dry thoroughly. The process was repeated several times in areas where either 1) the earth-tone bled through, or 2) a denser color was desired. The process was easy to repeat and was performed until we were satisfied with the results. We all use a common shade of Blended turf at the ends of our modules for consistency.
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Trees, clumps of vegetation, figures, vehicles, animals and other materials were added as a finishing touch to make the scene look as realistic as possible. Undiluted white glue was generally used to fasten these items as it dries to a clear finish. The fascias were given a final coat of paint and the module was readied for its début at a train show. The C-Track was returned to the base board, but only lightly tacked in place. Last minute adjustments were expected to be necessary when this new module was mated to its neighbors. Track power connections, overhead catenary, signals and ballast should complete the picture.
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Below is a picture of the new module, alongside other new modules, at the first public train show where the new modules were incorporated.
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