Super Bench

 02 May 22:

We are building another layout, our 6th, this one will be HO scale. We've done benchwork several ways, for this bench we want a sturdy platform as we have no plans to move it very far once it is constructed. We are going to build the frame with dimensional lumber, 4x4 legs and 1x4 joists, because this lumber is readily available and minimal carpentry is required. The stability of the bench is an investment towards protecting expensive electronic components on the layout, and no one wants a wobbly bench. We are calling it the "Super Bench."

While we used our trailer to transport the lumber, these pieces will also fit in most SUVs, or even our Subaru Outback.

We spent some time developing the track plan, then laid the plan out with the track we'll use on 1/2 inch rigid pink insulation foam. From there we decided what space we needed for buildings, sea ports, etc... and traced out what the total layout footprint will be. That foam footprint(s)  become the templates for the benchtop. Note: Not all of the foam in this photo will be used for our layout's bench, but we'll save the cutoffs to make hills and mountains.

Tip: We use Owens Corning FOAMULAR Extruded Polystyrene (XPS) Rigid Foam Insulation, found at builder supply stores (Home Depot). It can easily be carved to the bench shape and scenery, and it is much more dimensionally stable and dense than open cell styrofoam. We consider it essential for layout locations where there can be large temperature and humidity fluctuations, such as a basement or garage.

We hauled the foam sheet outside and cut the benchtop shape on the foam with a jigsaw. The green foam is the Lowes brand of XPS foam, in theory it would perform the same but this sheet will only be used as a template.

Next we laid the foam over the benchtop material and traced the shape. You might be wondering why we don't use the entire board? Our layout transitions through 2 corners of a room, and we would not be able to reach those far corners easily if we used the entire board. We are also creating aisleways were layout operators and visitors have room to move around.

Tip: We use 3/4 inch plywood for our benchtop. It will stay flatter than thinner plywood over longer spans, allowing us to space the joists underneath at greater intervals. The few extra pounds adds to bench stability. For spaces that have temperature and humidity fluctuations we'd invest in marine grade or exterior grade plywood. Another option we have used is medium density fiberboard (MDF), it is HEAVY. MDF will not hold fasteners well though, and fasteners will play a key role in connecting the benchtop to the frame and legs of Super Bench.

The jigsaw cut was mostly straight, so we use a straightedge to draw a better line as a guide for the next saw cut. The foam shape is not critical, but the plywood shape is, to have a nice looking and well built bench.

45 degree angles make future cuts easier to fit, and we use them when we can. 

...to be continued...