APPENDIX 2:  MODULE END PLATES

 

Gregg Fuhriman

 

1.      Endplates that are not vertical cause the following problems:

 

• When the tops of the endplates are tilted “inward” toward the body of the module, the ends of adjoining module track winds up further away from each other than the nominal 2”, requiring custom-length bridge rails to be made on-the-fly and really slowing down setup time.  And a large, unsightly gap in the scenery occurs as well.

 

• When the tops of the endplates are tilted “outward” away from the body of the module, there is a tendency during setup to tighten the C-clamp all the way down to force the bottoms of the end plates together.  This puts a lot of pressure on the end plate as the bottom edge tries to flex outward which may break loose framework joints, etc.

 

• Additionally, endplates that are not perpendicular to the module track cause problems by introducing sharp kinks in the trackwork as it passes to the next module.  Only the 2” long bridge rails are available to smooth out the kink, which is not enough length to handle anything bu the slightest non-perpendicularity.

 

• Any warping or twisting of endplates will also introduce variations and/or combinations of the above problems.

 

2.      End plates on existing modules, as well as during construction of new modules, can e checked using a carpenter’s “L” square.  One leg of the square is placed flat on the rail top while the other leg is allowed to hang down over the end plate vertically.  Gaps between the L-leg and the endplate then reveal problems in the vertical direction (tilt inward or outward).  Corrections can be made by carefully measuring and marking the endplate and removing material with a hand plane, belt sander, etc., to make the end plate perpendicular to the track vertically.

 

3.      For flatness, a 24” straight-edge may be used.  Slowly pass it over all areas of the endplate, watching for any revealing gaps between straight-edge and endplate.  These gaps will show where the “low spots” are on the endplate.  Carefully measure and mark the endplate and remove material to knock down the “high spots’, with frequent re-checks to avoid taking off too much material.

 

4.      Testing for track perpendicularity to endplate horizontally can also be done with the carpenter’s “L” square, with one leg against the side of the rail and the other leg along the length of the endplate (pointing at the module side)>  Correcting problems in this case is more difficult.  Either the track must be corrected or the endplate must be corrected.  Of the two, it seems the track would be easier to adjust, although on a finished, ballasted module, even that is a daunting task.

 

5.      The best solution is to avoid these errors in the first place.  When constructing end plates and module frames, double and triple check that endplates are flat and vertically perpendicular to the track subroadbed.

 

6.      When laying the track, make absolutely certain that it is horizontally perpendicular to the endplate surface.  The material used for endplates should be carefully considered.  Experience has shown that pine dimensional lumber is not stable enough.  It can warp and twist even after being assembled into a module.  High quality plywood is a better choice.  Other materials may work as well.