Starting new layout from the ground up...literally

[JoshH]

Looking great! It's always nice having the right tool for the job, especially when you have so much wiring to do. I'm not surprised Home Depot stopped carrying the wire, most likely not a super hot seller and they only have room on there shelves for things that move. Keep it up, you're moving quick!

[Silent1961]

Today I took a break from wiring. Two months ago today I started acquiring items needed to expand the 8' temporary loop into a larger temporary 6 corner loop. I then wanted to add a little interest so purchased a couple of turnouts. Began laying out track, trying out some different configurations. Then purchased a double crossover and a couple more turnouts to add a branch line and a siding. That lead to a couple more turnouts for staging tracks.

To sum up, I wanted an area to run trains with a longer run than the original oval when the desire hit while working on the "real" code 55 layout on the second deck. I took a hard look at where I'm at and came to a conclusion. I like what I see. I see so many possibilities. To the degree that I'm going to call this the main layout.

The Kato unitrack has grown on me. That being said this will not be exclusively Kato. There are a number of benefits to the system, but also some drawbacks that I will attempt a work around as this progresses.

This will be a single deck layout now with the upper deck becoming an independent second pike at a later date. That will not be unitrack.

2023-01-15 001 Slab Track to be Replaced.jpgThe repurposed slab track pieces will be replaced with ties. A second crossover, 1 LH and two more RH turnouts with new easements and corner pieces have been ordered. Arriving between Wednesday and Friday from various sources. The crossover is for the main where the current slab track resides.

2023-01-15 002 Tying Middle Stage to Branch.jpgThe left hand turnout is to tie in the center yard track lead into the branch so switching will not foul the main but provide plenty of room for working the yard.

2023-01-15 003 Industy Sidings.jpgThe right hand turnouts that I initially put in for the 2 industry sidings today, have been stolen.

2023-01-15 004 Staging Crossover.jpgThese are now a crossover at the end of the first and second yard tracks as a run around. I've added a curved lead to the first track after the new crossover.
2023-01-15 005 Staging Lead.jpg

That may change tomorrow after I do some testing on a potential extension in that area. If it works, I'll be transitioning from Code 80 unitrack to ME code 55 flex and built turnouts after the crossover for a particular scene I've wanted to do for years.
2023-01-15 006 Bench Extension 01.jpg2023-01-15 007 Bench Extension 02.jpg


So today was busy.

[MontanaModeler406]

Looking good!

[JoshH]

Do you mind sharing a few of the positives and drawbacks to the unitrack? I'm a Flex fan myself but the unitrack seems to be pretty popular.

[Silent1961]

Do you mind sharing a few of the positives and drawbacks to the unitrack? I'm a Flex fan myself but the unitrack seems to be pretty popular.

Positives;

For snap track, it is really robust. If you don't like a particular configuration, simply give the track piece (pieces) a twist to disconnect and rearrange the segments. I've changed track pieces constantly during this current layout build.

Easy to hide feeders. There are three options for attaching the feeders. Unijoiners at the connection points using either the Kato pre wired unijoiners or making your own by removing the coupler out of the plastic joiner, solder a wire to the bottom, place the coupler back into the plastic joiner and drop the wire below. There is also exposed rail directly behind the joiner pockets that allow for direct soldering the bottom of the rail. This permits a direct drop through the sub roadbed to the bus. I prefer the unijoiner method as the feeders can be removed from the track pieces and attached to other pieces (example; change from a 15" radius curve to a 19" radius curve) without having to soldering new wires onto the new piece. The third option is feeder track which plugs into the underside of the track direct then can be dropped or out to the side of the sub roadbed. I discovered 2 defective feeder tracks (1 single and 1 double) out of the seven I was going to use as I had them already.

The unijoiners allow effortless attachment of track pieces. It's pretty much bullet proof.

At each joint there is a very small gap between the rail ends which allow for expansion.

The built in turnout switch motors are under the track and requires no additional pin point accuracy for rods or unsightly table top machines. They can be thrown manually with the almost unseen lever. The wiring for the turnouts can be out either side or dropped directly below through the sub roadbed.

A small layout can be set up in hours (not including scenery), not days. It doesn't need to be secured to the sub roadbed so no waiting for glue or caulk to dry for road bed then the track. No nails either. If you bump the track, especially on larger layouts, it will shift but remain attached. Once I'm satisfied with the track placement I will be caulking it to the sub roadbed so I don't have it shift.

Negatives;

Expensive. Although flex has gone up substantially in price over the past couple of years starting with the great Atlas track shortage followed by Micro Engineering lack of product, Kato unitrack by the foot works out to be a higher cost. Most unitrack is also sold by the package. Not the individual piece. I needed 1 additional 19" radius curve but had to purchase a pack of 4.

Only #4 and #6 straight turnouts available. I have a few curved turnouts I need for part of the layout which I'm still going to have to make. I can run the main and the branch but will be delayed in completing the track laying. I also want a #10 turnout in one location which again I'll have to manufacture. Kato does have a transition track from unitrack to flex. I'll be using a total of 5, which come in packs of 2, for the sidings and engine facility.

You are restricted to the radius and degrees Kato produces. There are a couple of spots I only wanted a small length of large radius curvature but the smallest available was 15 degrees at 7-5/16" length for the 28-1/4" radius. the next size down was 19" radius and nothing larger than the 28-1/4" at this time. Nothing in between those two sizes are available.

For any custom configuration, the variety track piece packs are needed to maintain alignment. Until the loop is connected it's unknown what exact size is required. There are different contents for size variants in each specific pack. I needed pieces from each. 62mm and 64mm are slight in length difference (by a 1/16") but is enough to cause a slight kink if if the wrong one is used. This is where flex shines. I have seen YouTube videos where track pieces have been modified but at the price, I don't want to create something that may make the piece unusable. Like I said, if the track piece is off slightly, especially on a smaller layout, it could cause a kink.

With the built in roadbed, the track looks toyish out of the box. This is minor as ballast can be added and we have to ballast our flex so no real extra effort takes place.

The biggest negative for me is the track is only available in code 80. I like my code 55 rail, and will have some incorporated into this layout. Saying that, the code 80 unitrack is growing on me.

I've been a flex guy for close to 30 years so this change is similar to when I switched from Atlas sectional track to flex. It's different. There is also Tomix track which is very similar to unitrack and has more options. The deterrent for me is the lack of local availability. The LHS carries a fair amount of Kato unitrack in stock. Not a single piece of Tomix.

My final opinion is the benefits far out way the negatives. I'll be fully functional in less time than going the flex route which is my goal for the lower deck. When I get back to the upper deck, I can take my time. Days I don't want to work on the layout, I will have the ability to relax and just run trains. Kato unitrack is also great for those who don't have space for a dedicated layout. Quick to set up and just as quick to tear down. A dining room table, or even a folding table will suffice for sitting in a chair or standing while operating. It can be laid out on a floor if the body allows that positioning. Do not run it on carpet. The fibers will get into the locomotives and cause a whole other issue.

[donzi]

It's looking great Grant.
Will you be using Kato c80 flex?
Enjoying following your build.

[Alan L]

Is it difficult to mix flex where needed with the kato track?

[Silent1961]

It's looking great Grant.
Will you be using Kato c80 flex?
Enjoying following your build.

Good question. No I won't be. I have some left over Atlas code 80 flex that I'm going to use for the future scratch built engine facility. It fits like a glove with the unitrack conversion piece. I tested it before committing to its usage. In another scene I'll use ME code 55 as I'll need to build some custom turnouts. All my Fast Tracks materials are code 55 which dictates the track. I'll use the code 80 joiner smash method for the transition.

[JoshH]

Thanks for the very detailed reply, it's been so long since I last bought track and with all the shortages lately I was debating switching gears a bit and I have absolutely no experience with any of the snap track so it's nice to hear some solid feedback

[Silent1961]

Played around with the benchwork today.

2023-01-16 001 Extension Added.jpg I added a 7-1/2" extension above the bench matching the duck under profile. This makes the overall depth in this area at 36", which I have full access from both sides so no reach issue.

2023-01-16 002 Extension Donor.jpg I cut the addition from a 2' x 4' diorama module I made up years ago and has been in the way ever since. This is why there is cork on the new piece. Unfortunately the cork is too thick to match the roadbed and I only have the small square remaining to add. I have another new 24"x 48" roll of thinner sheet cork which I'll use in this area. Hopefully I can remove this old stuff without damaging the foam under it too badly.

2023-01-16 003 Corner Extension Test.jpg I then played with the placement and angle of a plywood piece to extend the 12" deep section forming the near side of the access. I first tried a 45 degree angle (not pictured). Outside of the overhang restricting my ability to stand up from the workbench without smacking my head, the reach across the peninsula was unrealistic. Despite having access from 3 sides. I then tried a 35 degree/55 degree angle (pictured). Still too close to the bench to prevent head contact. I hit my head twice so it wasn't speculation. Reach capability may be doable but not easily achieved.

The extra real estate is definitely promising for the scene I want to create in this area. I'll try a 30 degree/60 degree cut tomorrow.

[Silent1961]

Continued with benchwork today.

I was successful in lifting up the old cork with very little damage to the foam underneath. My 15 in 1 tool was very effective.



The 30 degree/60 degree angle works. The framing is now complete with the exception where the 2 clamps are supporting the cross members to the existing benchwork. This will add 43" in length and 23" in width at the widest point.



On the backside, I also framed up a small section that is lower than the main sub roadbed. This will have a beach scene which will extend into the 1-1/2" foam to the left for about 3 feet. I still have to do the plywood deck for both sections.

[Silent1961]

Installed the new turnout tying in the center yard track lead into the branch. Hooked up the feeders to the DC side of the double main in what will become district 1.
2023-01-25 004 Lead Turnout Installed.jpg

Put in the two replacement turnouts for the sidings. This too has the feeders into the DC side of the double mainline in district 1.
2023-01-25 005 Siding Turnouts Installed.jpg

The four slab track curves have been replaced. Still waiting on the last easement to arrive at the LHS to finish off the mainline. The ties are a marked improvement.

2023-01-25 007 First of 4 Slab Track Corners Replaced.jpg

Connected all the rest of the district 1 DC feeders to the DC bus. Ran a locomotive through the district 1 trackage and the three new turnouts. Worked flawlessly. The DC powered track is temporary. As more locomotives become decoder equipped, this will be a full DCC layout. The feeders are dropped every 3 feet and will be easily transferred to the DCC bus when the time comes. District 1 is the west side lower level. District 2 will be the east side lower level. Districts 3 and 4 will be the upper level which is way down on the list of priorities at this time.

The last task completed today was cutting the 1/2" plywood sub roadbed for the angled benchwork extension and screwed it down after securing the last two cross braces.
2023-01-25 008 Benchwork Extension Completed.jpg

Next project is to create cradles for the turnout controls in two locations.

[Alias]

Do you mind sharing a few of the positives and drawbacks to the unitrack? I'm a Flex fan myself but the unitrack seems to be pretty popular.

What Silent1961 said above is pretty much right on. My layout is 100% Unitrack with a Tomix bridge (FineTrack). I just wanted to add one more to the Kato negative column; the notorious #4 Turnout (part number 20-220/221). Cars tend to derail going over #4 turnout, due to the way the point rail sits on the stock rail. The issue has been discussed ad nauseam all over the inter web. Considering this is a Japanese product, I’m surprised they really haven’t addressed this particular problem since it’s been going on for a long time now. Then again may be Japanese trains (Kato) don’t derail on these (all mine are German prototype).

[Silent1961]

Finished up the cradles for the turnout controllers today. First one holds 10 just above the command station location. From this location I have full visibility of 8 turnouts and the 2 double crossovers.

2023-01-29 001 Main Turnout Control Cradle.jpg

The second cradle holds 4 turnout controls for the 4 turnouts which will not be easily visible from the command station.

2023-01-29 002 Secondary Turnout Control Cradle.jpg

I then used some of the turnout number labels that come in the package with each controller and using T-Pins, labelled each turnout. I also labelled the plug end of each turnout for ease of identification as I plug them into the corresponding controllers.

2023-01-29 003 Turnout Labels.jpg2023-01-29 004 Turnout Connector Labels.jpg

I have easy access to the controller backs for installation and removal of the plugs as needed. I'm just waiting on some Wago connectors for connecting the DC conversion module to the AC accessory bus, which I still have to run. I will need to remove the cradles when I put in the facia. The Wago connectors will facilitate disconnecting the power module when the time comes.

2023-01-29 005 Turnout Control Plugged In.jpg

I finished up the day by cutting the foam for the angled extension and started piecing in some scrap foam for the industry area. I still have to plan out this area to see if I can fit in the 8 tracks and the 12 turnouts I want on this extension.

2023-01-29 006 Foam for Extension Cut.jpg2023-01-29 007 Foam for Extension Cut.jpg

Next up is to finish the bus wire rough in for the last upper deck district before I get any further on the lower deck. I don't want to damage any work done on the lower deck because I waited to install what is easily accessible now.

[Silent1961]

Picked up 30 more feet of each 12g red and blue stranded wire to finish the DCC bus rough in on the upper deck for district 3. I have this secured with clamps and screws so it is out of the way. I can removed the screws to provide slack when it comes time to connect feeders. I continued into district 4, the other side of the upper deck, and went as far as I could securing that bus wire as well. All the stuff I have on the floor is in the way to finish that task. I want to finish all the wiring in district 1 first as it will be buried when I move everything from one side of the shed to the other for districts 2 and 4 access.

2023-01-30 001 District 3 Wiring.jpg2023-01-30 002 District 3 Wiring.jpg2023-01-30 003 District 3 Wiring.jpg

With the 3 sets of bus wires and feeders, I'm now at a little over 500 feet of insulated copper strung up around the layout. With more to go for hooking up the turnouts to controllers, turnout bus, Arduinos, Tortoises and Azatrax boards/IR sensors.

I was planning to connect the DCC system tomorrow with the PM42 circuit breakers until I read the instructions and saw how small the pins are on the edge connector to solder the bus wires to. It's going to be an all day project at least. I think I'll wait until Wednesday and focus on connecting the turnouts instead. I have some extensions I have to make and run that bus to have a sense of project completion. Time permitting, I'll also hook up the pig tail feeders into the DCC bus for district 1.

[Heiko]

[...]PM42 circuit breakers until I read the instructions and saw how small the pins are on the edge connector to solder the bus wires to.

JFTR: There are breakout boards and edge connectors available to help you with that. A quick google search turned up these connectors from Digitrax themselves: https://www.digitrax.com/products/ac...rdedge-con-44/ (which may or may not make soldering easier, I'm not sure, but at least you'd be destroying a $4 connector instead of the entire PM42 if things fail...) and these breakout boards from Acculites: https://acculites.com/index.php?main...roducts_id=574

I have no personal experience with either, and you might well find more if you look past the first page of search results and this entire post is just for the record, so you have all the information available.

Heiko

YMMV,
Heiko

[Silent1961]

JFTR: There are breakout boards and edge connectors available to help you with that. A quick google search turned up these connectors from Digitrax themselves: https://www.digitrax.com/products/ac...rdedge-con-44/ (which may or may not make soldering easier, I'm not sure, but at least you'd be destroying a $4 connector instead of the entire PM42 if things fail...) and these breakout boards from Acculites: https://acculites.com/index.php?main...roducts_id=574

I have no personal experience with either, and you might well find more if you look past the first page of search results and this entire post is just for the record, so you have all the information available.

Heiko

YMMV,
Heiko

Good to know. The PM42 comes with an edge connector. In the back of my mind, I was wondering that if I botched up the job if replacements were available. Hopefully I won't need to order any if I do it right the first time. I already checked that the 12g will fit within the width of the pins but there is very little room for error if not exact. My helping hands are definitely going to be put to use with my magnifying lamp.

I need to rearrange my terminal strip positions to minimize the stress on the connections as the input and output wires flow in the same direction at the PM42. I also have to mount the PM42 in such a way I still have access to the LocoNet ports that are on the opposite end of the board. I need to leave room to mount my PR4 with access to the connection points for power, LocoNet ports and the USB connection in the same area. The PR4 position will dictate where my programming track will be located and hopefully still be close enough for connecting to my laptop without a USB extension. It's all doable. Just more work than planned diminishing the "fun" factor a bit.

[Silent1961]

After working on the to-do list for the boss the past couple of days, I finally got back into the train room today. I ran the bus wires for the Kato turnout controls, connected them to the accessory terminals on the Railpower 1300 and connected the DC converters to the bus with the Wago connectors that arrived Wednesday. Tested the switches and nothing happened.
2023-02-05 AC Bus Connected.jpg2023-02-05 District 1 Turnout Controllers Connected.jpg2023-02-05 District 2 Turnout Controllers Connected.jpg

After a couple of hours trouble shooting, discovered the fix was to trim 1/16" of insulation off the DC converter wires for the Wago connectors to make solid contact. The 11 turnouts and 1 crossover that are connected all work now.

I labelled the turnout locations onto the controller cradles for reference until I get used to which turnouts control what location. When scenery starts, the T-pins will be gone. It took a few minutes to refresh myself on the turnout locations this morning and I was only away from the layout for 3 days.
2023-02-05 District 1 Controllers Labelled.jpg2023-02-05 District 2 Turnout Controllers Labelled.jpg

Next up is to get the Evolution hooked up and start connecting feeders for the DCC side of the layout in district 1.

[Silent1961]

Today was spent connecting the DCC system. Pulled out the DCS210 and hooked up the unit to the terminal strip. 2023-02-07 002 DCS 210 Connected.jpg


I repositioned the first terminal strip up a bit for when I connect the PM42 circuit breakers. The district 1 wires are connected direct to the output terminal strip to test the command station circuit protection as per the PM42 directions. Until I get district 2 wired up I won't install the PM42. I also labelled the various connections on the board while it only has the one set of wires between the terminal blocks. It's not as pretty as @Sumner set up, but is functional. The output terminal strip will be moved up before I install the PM42.

2023-02-07 003 District 1 Wired.jpg


I then soldered the first pigtails to the main bus which connected the first set of feeders for the 5 tracks in the area. I turned on the command station with the throttle connected direct to ensure everything was operational. Tested the short protection and all is good. I then installed a UP5 temporarily to where the facia will go. Hooked up the throttle and put my GMD-1 sound unit onto the main.

2023-02-07 001 First Set of DCC Feeders Soldered.jpg2023-02-07 004 Temporary UP5 Mounted.jpg


The loco did not do well and this one has a couple of hours on it so I know it's broken in. I spent the rest of the day cleaning the tracks with mineral spirits. We'll see what improvement that makes tomorrow.

[Silent1961]

I will never use mineral spirits to clean the track again! The residual odor kept me from spending time in the shed for the last 4 days. It settled down enough that I could do some work today.

I have now connected all the district 1 feeders to the bus. Soldered the 6 sets of 18g pigtails to the corresponding A and B rails. I ensured each joint was soldered at different points on the bus to prevent accidental contact with each other.

2023-02-12 001 Feeder Pigtail Soldered.jpg

Then applied a liberal amount of liquid tape to ensure there was no possibility of a short.

2023-02-12 002 Liquid Tape.jpg2023-02-12 003 Solder Joints Sealed.jpg

I then ran the same GMD-1 over all the district 1 trackage.

2023-02-12 004 Testing.jpg2023-02-12 005 Testing.jpg2023-02-12 006 Testing.jpg

It stalled occasionally at turnout #6 when a slow speeds, and shut down when I ran it through the turnout onto the branch which only has 1 feeder before the isolation joiners separating district 2. So the track cleaning and connection of the additional feeders made a significant improvement to the locomotive operation. Tomorrow I'll add a second set of feeders to the branch just after the turnout and see if that solves the issue.