Hi folks I'm building benchwork for a 1.5x3.5m HO layout (ok ok 5'x12'). Trackplan here South Pacific Lines I will need to move it some time this year for renovations. It will have to break into two to get through doors, but no more: the track plan has lots of turnouts making it hard to divide into pieces. I want two people to be able to carry it out and put it back later. I've been inspired recently by several people talking about lighter benchwork, so I thought this was an opportunity to experiment. To keep weight down, nothing rides for free: every part is supposed to contribute to the structural strength: the track base, the fascia, the backdrop. Also there is very little scenery on my plan - I will use space-filler foam to avoid the weight of plaster. I've built an open-grid frame from galvanised channel. It's extremely light C-section sheet mild steel, about 1"x1". I think it is used to carry wiring?? It has quite good rigidity except torsional (twisting). And it is cheap. I screwed it to the walls and to 1"x2" pine legs. I'm very happy with the strength so far, though I wouldn't want to climb on it Next layer will be foam sheet and here's where I need some help/advice. I'm thinking to use 50mm (2") sheet. To increase its rigidity I'll cut some 100mm (4") strips of it and gluing them edgewise between the underside of the sheets and the galv frame work to make a box structure. Questions: how rigid is the foam sheet over longer distances 6'-12'? Do folk use the harder extruded foam or just expanded foam? do you like the sound of the design? How is foam for track noise?
It is the harder foam you buy from places like Home Depot, the pink and the blue stuff, that is used, not the beaded foam. Even three quarters inch plywood has to be braced every 16 inches or so. Put support in for the foam and longer expanses aren't a problem. Design sounds good. Sound on the foam isn't an issue.
