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Project file: lionel layouts in a box

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Christopher Kanski
Christopher Kanski

This document describes the design and construction of a portable Lionel train layout that fits in a custom hard case measuring 61" x 24" x 5.5". The layout was designed to be easily portable and set up by one person in small living spaces like under a bed or in a closet. It uses Lionel FasTrack for its stability and larger 32" radius curves. Scenery includes a hill, rocks, lake, buildings and figures to make the small layout feel more expansive. The innovative 3-piece hard case design allows the two layout halves to securely connect without any cuts or joints in the track.

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Lionel Layouts In a Box
Objective Create a portable Lionel train layout that could be carried and set up by one person and store underneath a twin bed or in a closet. Background The inspiration for this project was a family relation and longtime rail fan who was residing in a nursing home. I had become the custodian of his train collection because in this situation, there seemed no way around the oft-heard lament that, there is no room for a model railroad. It seemed a shame to me that something capable of providing great joy would be denied because of a lack of imagination. Surely a portable, suitcase- styled model railroad could be accommodated and permit him to run his impressive collection of 1950s vintage equipment. The only problem was his equipment was Lionel O-gauge. Design There were many constraints on this design beyond the challenge of working in O-gauge. Fundamentally, it had to be it had to be rugged, reliable, and simple for anyone to set up. Additionally it had to store either vertically in a closet or under a twin bed and be easily lifted by one person. From these requirements I set overall stowed dimension limits of not greater than 66 x 30 x 6. The go/no go test for the project was to determine what kind of layout would fit within these dimensions. I chose Lionel FasTrack because although it had a larger (32) radius curves than 0-27 track, it provided greater stability and a more secure connection between track segments. The larger radius permits the use of true O-scale in addition to O-27 equipment and provides a somewhat grander sweep to an admittedly limited mainline. Buying Lionels NYC Flyer kit proved to be the most economical way to obtain all the required track work plus the transformer and a complete train to boot. With the track plan established, the case could be precisely sized with outside dimensions of 61 x 24 x 5.5. 1 of 6 Lionel Layouts In a Box Lionel Layouts In a Box
Construction Clearly the case would be key to the project. A custom wood box was an option, but heavy. Guitar cases seemed promising, but my constraints were too specific, so I contacted some custom case companies to see what was possible. To my surprise, several companies were able to quote custom cases fabricated from a variety of materials, at reasonable prices. Turns out the music industry creates a demand for odd cases to enclose all the equipment needed to support a road show. By using common hardware and trim components they could cut extruded plastic sheet of any size to order and assemble a custom case for a few hundred dollars. The largest obstacle was making the case able to fold flat in such a way that the track laid in the two halves would be able to smoothly join. With a hinged case, this would have required several cuts in the base, complicating the joint, weakening the structure, and driving up costs. Instead, the key innovation was to use a three-piece case in which the two layout halves are closed by a short detachable end cap. This solution eliminated the difficult hinge and permits joining the two halves without the need for a jumper track, since the track on each half can project into the end cap. Furthermore, by alternating the orientation of the latches, the same hardware used to close the case is employed to lock the two layout halves together during operation. To provide an adequate roadbed for the track and sufficient rigidity to prevent the scenery from flexing, a 3/16 thick plywood sheet was installed as a foundation to build on. With the case now in hand and the track plan determined, the vision for the remainder of the layout came clearly into focus. One side would have high terrain features in order to provide storage for the locomotive and rolling stock; the other side would necessarily have low terrain features. This translated into a hill and a lake. 2 foam insulation board was used to create the hill and the rocks were cast with Woodland Scenics Foam Putty in standard rubber molds. Though somewhat expensive for applying to a 1 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Layout during construction
large area, Foam Putty produces much lighter rock molds than traditional plaster casting. Its important to be sure the mold is clean and coated with a mold release agent. Once filled with foam putty, it must be allowed to dry completely, a process that could take a day or two, before carefully peeling back the rubber. The result will have all the detail of a plaster casting with a fraction of the weight. These castings were glued into place with acrylic Liquid Nails. After they had dried, some additional Foam Putty was rubbed into the seams with a finger to blend them into their surroundings. Epoxy resin has become the common choice for modeling water, but with such a large area to cover, the weight and potential for cracking was a concern. I decided, instead, to use an old technique that works well with larger scales, namely painting the smooth side of a suspended ceiling lighting panel. The faceted side provides a good illusion of wavelets in this scale and the panel guaranteed uniform flatness and maximum thinness to accommodate the raised storage hill in the opposite half of the case. The beach was an afterthought to fill a corner but again its the painting that creates the illusion and a few whitecaps go a long way. To create the pastures, felt was glued to the surface and then teased with a wire brush. The wood structures were scratch- built and weathered with a strong India ink wash. The station house was designed to modestly cloak the transformer, which is mounted to the plywood base. It is hardwired to the layout, making setup as easy as taking off the bottom piece of the case, locking the two halves together and plugging in the transformer. The judicious use of figures to create mini-scenes can make a small layout feel much larger. Lots of activity at the station distracts from the extreme curvature of the platform and makes the empty portions of the layout feel further away . Even within this scene, the boys with their bikes forms another sub-story, adding storytelling depth. The lone figures fishing and at the beach emphasis the emptiness of the scene, making it feel larger. A little experimentation can get just the right feel. 3 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Testing storage and portability The connector cap
4 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Scenes along the rails
5 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Scenes along the rails
6 of 6 Lionel Layouts In a Box Lionel Layouts In a Box I hope this project is an inspiration for those who feel their railroad dreams, especially if you dream in large scale, are precluded by lack of space. Large scale trains have an appeal and a practicality to children and seniors alike. Whether its in childrens hospitals or nursing homes, or anywhere space is an issue, this article is proof that the suitcase-sized Lionel layout isnt a contradiction in terms. With a little precise imagine there is always room to realize the joy a model railroad can bring.

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Project file: lionel layouts in a box

  • 2. Objective Create a portable Lionel train layout that could be carried and set up by one person and store underneath a twin bed or in a closet. Background The inspiration for this project was a family relation and longtime rail fan who was residing in a nursing home. I had become the custodian of his train collection because in this situation, there seemed no way around the oft-heard lament that, there is no room for a model railroad. It seemed a shame to me that something capable of providing great joy would be denied because of a lack of imagination. Surely a portable, suitcase- styled model railroad could be accommodated and permit him to run his impressive collection of 1950s vintage equipment. The only problem was his equipment was Lionel O-gauge. Design There were many constraints on this design beyond the challenge of working in O-gauge. Fundamentally, it had to be it had to be rugged, reliable, and simple for anyone to set up. Additionally it had to store either vertically in a closet or under a twin bed and be easily lifted by one person. From these requirements I set overall stowed dimension limits of not greater than 66 x 30 x 6. The go/no go test for the project was to determine what kind of layout would fit within these dimensions. I chose Lionel FasTrack because although it had a larger (32) radius curves than 0-27 track, it provided greater stability and a more secure connection between track segments. The larger radius permits the use of true O-scale in addition to O-27 equipment and provides a somewhat grander sweep to an admittedly limited mainline. Buying Lionels NYC Flyer kit proved to be the most economical way to obtain all the required track work plus the transformer and a complete train to boot. With the track plan established, the case could be precisely sized with outside dimensions of 61 x 24 x 5.5. 1 of 6 Lionel Layouts In a Box Lionel Layouts In a Box
  • 3. Construction Clearly the case would be key to the project. A custom wood box was an option, but heavy. Guitar cases seemed promising, but my constraints were too specific, so I contacted some custom case companies to see what was possible. To my surprise, several companies were able to quote custom cases fabricated from a variety of materials, at reasonable prices. Turns out the music industry creates a demand for odd cases to enclose all the equipment needed to support a road show. By using common hardware and trim components they could cut extruded plastic sheet of any size to order and assemble a custom case for a few hundred dollars. The largest obstacle was making the case able to fold flat in such a way that the track laid in the two halves would be able to smoothly join. With a hinged case, this would have required several cuts in the base, complicating the joint, weakening the structure, and driving up costs. Instead, the key innovation was to use a three-piece case in which the two layout halves are closed by a short detachable end cap. This solution eliminated the difficult hinge and permits joining the two halves without the need for a jumper track, since the track on each half can project into the end cap. Furthermore, by alternating the orientation of the latches, the same hardware used to close the case is employed to lock the two layout halves together during operation. To provide an adequate roadbed for the track and sufficient rigidity to prevent the scenery from flexing, a 3/16 thick plywood sheet was installed as a foundation to build on. With the case now in hand and the track plan determined, the vision for the remainder of the layout came clearly into focus. One side would have high terrain features in order to provide storage for the locomotive and rolling stock; the other side would necessarily have low terrain features. This translated into a hill and a lake. 2 foam insulation board was used to create the hill and the rocks were cast with Woodland Scenics Foam Putty in standard rubber molds. Though somewhat expensive for applying to a 1 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Layout during construction
  • 4. large area, Foam Putty produces much lighter rock molds than traditional plaster casting. Its important to be sure the mold is clean and coated with a mold release agent. Once filled with foam putty, it must be allowed to dry completely, a process that could take a day or two, before carefully peeling back the rubber. The result will have all the detail of a plaster casting with a fraction of the weight. These castings were glued into place with acrylic Liquid Nails. After they had dried, some additional Foam Putty was rubbed into the seams with a finger to blend them into their surroundings. Epoxy resin has become the common choice for modeling water, but with such a large area to cover, the weight and potential for cracking was a concern. I decided, instead, to use an old technique that works well with larger scales, namely painting the smooth side of a suspended ceiling lighting panel. The faceted side provides a good illusion of wavelets in this scale and the panel guaranteed uniform flatness and maximum thinness to accommodate the raised storage hill in the opposite half of the case. The beach was an afterthought to fill a corner but again its the painting that creates the illusion and a few whitecaps go a long way. To create the pastures, felt was glued to the surface and then teased with a wire brush. The wood structures were scratch- built and weathered with a strong India ink wash. The station house was designed to modestly cloak the transformer, which is mounted to the plywood base. It is hardwired to the layout, making setup as easy as taking off the bottom piece of the case, locking the two halves together and plugging in the transformer. The judicious use of figures to create mini-scenes can make a small layout feel much larger. Lots of activity at the station distracts from the extreme curvature of the platform and makes the empty portions of the layout feel further away . Even within this scene, the boys with their bikes forms another sub-story, adding storytelling depth. The lone figures fishing and at the beach emphasis the emptiness of the scene, making it feel larger. A little experimentation can get just the right feel. 3 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Testing storage and portability The connector cap
  • 5. 4 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Scenes along the rails
  • 6. 5 of 6 Lionel Layouts In a Box Lionel Layouts In a Box Scenes along the rails
  • 7. 6 of 6 Lionel Layouts In a Box Lionel Layouts In a Box I hope this project is an inspiration for those who feel their railroad dreams, especially if you dream in large scale, are precluded by lack of space. Large scale trains have an appeal and a practicality to children and seniors alike. Whether its in childrens hospitals or nursing homes, or anywhere space is an issue, this article is proof that the suitcase-sized Lionel layout isnt a contradiction in terms. With a little precise imagine there is always room to realize the joy a model railroad can bring.