VIRTUAL SWITCHING ON THE NCIR!

I've met a lot of great people in this hobby.  Ken, who's Dawson Station Layout is a small masterpiece, generously created a virtual version of my New Castle Industrial Railroad.  Thanks to Ken's creativity, you can now try your hand at shifting the mill.  (Please note that this simulation combines the dock and warehouse  tracks into a single spur.)     

Simply click on a specific car to view its destination.  Zoom in and out using the '+' / '-' keys, or move the layout left and right using the arrow keys.  Click on the switches to throw them.  

I've included a switch list below, similar to what crews would receive at the beginning of the day.  For a bit of background, you may wish to refer to my Trackplan and Operations and Layout Tour pages.  Have fun!  

You can scroll all the way down to the end of the page to see how the work was done on the 1:1 :-) 

NCIR Work Order:  PCA -- New Castle   1 November 2005

PCA DOCK

ABX 552     Paper Scrap     No Bill  (Car goes on storage track b/c rr hasn't received paperwork) 

CSX 866     Paper Scrap     Pull  (Car goes to interchange)

PCA WAREHOUSE

NS 638       Empty     Pull   (Car goes to interchange)

RBX 251     Empty     Pull   (Car goes to interchange)

RBX 801     Empty     Respot - Dock  (MTY car goes to dock for scrap paper loading)

NS 621       Empty     Pull    (Car goes to interchange)

STORAGE

RBX 605     Linerboard     Spot - Warehouse

CSX 174     Linerboard     (This car not needed, stays on storage track)

AGR 034     Linerboard     Spot - Dock

CLX 012     Corn Starch    Spot - Warehouse 3rd from door

INTERCHANGE

CSX 514     Linerboard     Spot  - Warehouse

CSX 258     Linerboard     (This car not needed, goes to storage track)

RBX 772     Linerboard     Spot - Warehouse

One way of doing it:

Run locomotive down and couple to cars on the interchange track.

Inspect all cars and conduct brake test (on the layout this means admiring my cars and locomotive:-)

Uncouple RBOX 772.  Pull the other two inbound cars clear of the switch.

Still holding the two inbound boxcars, shove ahead and couple onto the cars standing on the storage track.

Pull everything clear of the switch.  Then shove ahead on the interchange track and couple to the lone RBOX 772.

Make a cut and leave the CCLX 012 starch hopper and AGR 034 with the RBOX.

Pull back clear of the switch.  Shove ahead into the storage track and set out  all four loaded boxcars that remain coupled to the engine. 

Pull back again to clear.  Run ahead onto interchange and couple to the three cars.  Make a cut , then pull back with just the AGR 034 to clear the switch.

Shove into the storage track and couple.  Make a cut and drop CSXT 174. 

Pull back to clear with all the other cars.

Shove ahead onto the interchange track and drop RBOX 605.  

Pull back, then drop CSX 258 on the storage track, coupled to the CSX 174 car you dropped earlier.  Make sure to leave enough headroom on the storage track so you can drop one more car in there a bit later.

Pull back, then shove onto the interchange track and set out CSX 514 and AGR 034.  Now all our cars are lined up for spotting on the PCA spur.  

Pull back. (Now you just have the light engine).  Go into the plant spur.  Couple all cars together from dock and warehouse.  

Pull back until the last car (NS 621) is just short of the fouling point.  Cut and leave the NS car on the spur.

Pull back to clear the switch.  Shove ahead and drop RBOX 801 with the cars already on the interchange track. (Now we have all 6 of our cars for the warehouse and dock lined up in spot order).

Pull back to clear switch.  Shove into the spur and grab the lone NS car (621).  

Pull everything back again to clear the switch.  Shove ahead and couple to cars on the interchange.  

Pull the whole string clear of the switch.  Then shove ahead into the spur.  Spot the 4 warehouse cars.  Then cut, pull back and spot the two dock cars.  

Pull everything else back to clear the switch.  The "no bill" ABOX 552 should be coupled right to the engine, followed by all the MTY's destined for the interchange.

Shove ahead and drop the 4 MTY's on the interchange.  Pull back.

Shove ABOX 552 into the storage track.  Pull the engine back to clear the switches.

DONE!!

A CLEARER PICTURE

Last time I mentioned that I placed temporary track down on the layout, simply to judge how all elements will fit together.  The overall picture is coming into sharper focus and I'm happy with what I see!

That being said, allow me give you a tour of the New Castle Industrial Railroad :-)

We are standing near the right end of the layout at what is known as New Castle Junction (the eastern limit of NCIR ownership).  The track running diagonal across the layout is the Conrail (now CSXT) main.  The boxcars are on the CSXT/NCIR interchange track.  The track in the foreground is the former Conrail New Castle Secondary main, now used by the NCIR as a storage track.  There used to be a diamond crossing here, but it was removed when Conrail abandoned the New Castle Secondary east of the crossing.  I  plan to model the abandoned, overgrown ROW.  The CSXT main will be well maintained code 148 rail on a nice bed of ballast.  In contrast, the NCIR's track will be lighter weight.  There will be a rusted signal standing guard at the former diamond, along with the foundation remains of a tower.  Long ago, many trains must have passed through here every day!

Above is an aerial view of the junction.  Note that the interchange track does not actually connect to the CSXT main.  Rather, it climbs upgrade to join the main somewhere in the "off-stage" distance.

We are now looking due west down the New Castle Industrial.  The CSXT main is in the foreground.  Left to right we see (1) the old Conrail main, now used for car storage; (2) the NCIR/CSXT interchange track; and (3) Packaging Corporation of America's warehouse and dock track (where the cars are spotted in the upper right of the photo.

Looking east.  Left to right: PCA's dock track (which will be on a higher grade); interchange track and old main.  Cars are drilled into spot order using the interchange and old main.  Overflow cars waiting to be spotted are stored on the old main.

Picture an outdoor dock here, between the RBOX and the backdrop.  Then picture a large warehouse where the cars in the background are spotted.  The dock is where empty boxcars from the warehouse are reloaded with scrap cardboard.  Tank cars of caustic soda are also unloaded here.

Loads on the old main waiting to be spotted.  A conductor spends a lot of time here, shifting out cars requested by PCA on a given day's switch list.  In the distance is NCIR's RS-11, tied down awaiting the next day's switching chores.

 

Above is an overall view of the layout.  I'm excited!  I think the O Scale New Castle Industrial will offer good operation and a variety of neat scenic elements in 18 lineal feet. 

We'll conclude by looking at the left end of the train room.  A long switching lead (staging track) will wrap around the far wall and over my cabinets.  The track will be on a narrow wooden shelf.  If I ever expand, I'll widen a portion of this shelf and add a chemical plant in the left corner, served by another trailing point switch.  However, I'm getting way ahead of myself here:-)

And just for fun...

I recently found this photo from August 2007, when we first looked at the house with our Realtor.  This was the previous owner's workshop and storage room, which is now my railroad room.  These last two photos were taken from roughly the same spot.  Boy, the previous owners had a lot of stuff!

Thanks for taking the tour!!

Jack

RS-11 no. 318

The locomotive assigned to the NCIR is Alco RS11 #318, a former Kankakee, Beaverville & Southern ex BN nee NP unit.  

In reality, the locomotive is a brass import from Overland Models with a rebuilt drive train from Doug Cockerham.  

 

 

This engine is a dream to switch with.  I can come in with speed, ease into a smooth coupling, then stop and stretch the slack just as we do on the 1:1

Here is a video of my RS-11 drilling cars: 

O scale New Castle Industrial Railroad from Jack Hill on Vimeo.

Eventually, I will get the engine painted and weathered.  The locomotive will wear a well worn coat of blue and yellow, (like its former owner, the Kankakee Beaverville & Southern) with patched NCIR reporting marks.

Former KB&S RS-11 #321 now drills grain hoppers for the CO-OP elevator in Darrow, Illinois.  When KB&S retired their Alco fleet in favor of newer EMD power, several of the veteran workhorses migrated to shortlines and industrial switching operations. 

BENCHWORK

Hollow-core doors, $19.99 each from Home Depot, made benchwork construction a breeze.  I fastened the doors to a 1" pine ledgerboard along the walls and used knee braces for support.  I designed my benchwork to be portable in case we ever have to move.  The layout sections are simply lag-bolted together as shown in the photo.

The resulting benchwork is quite rigid and easily supports my body weight.

I used green foamboard insulation from Lowe's as a scenery base.  I initially used three inches of foamboard, which resulted in a track height of 53" off the floor.  Upon placing temporary track and structure mock-ups, I found that 53" was a tad too low for my taste.  I added another 2" layer of foam to bring the benchwork height to 55".  I'm 5' 10" and 55" is about armpit height.  I tested operations again before permanently attaching the additional foam layer, just to make sure that I could manually uncouple cars anywhere on the layout.  The resulting 5" foam base layer allows for plenty of scenery below track level.

I used a hand saw rather than a utility knife for cutting foam, cleaning up the edges with a drywall sanding block.

PL300 is a great adhesive for attaching foam.  

WILBUR CHOCOLATE

This is the Wilbur Chocolate factory in Lititz, Pennsylvania.  Wilbur receives inbound hoppers of sugar from NS.   I really like the way the terrain slopes uphill, both to the rear and left-to-right.  The building itself just begs to be located at the corner of a shelf layout.  

I notice more subtle details each time I visit and photograph the factory.  Check out the truck dock between the main and the spur.  There is just enough lawn and landscaping to give the hint of late fall.  Also, the variety among the buildings themselves is terrific.   

 

AERIAL PHOTO

GOOGLE MAP IMAGE

MICRO SHORTLINES

Here are a couple real-life examples of neat industrial rail operations:

The first example is located in picturesque Manheim, Pennsylvania. Manheim is in the heart of Amish country in Lancaster County. Here, the Manheim Industrial Railroad operates a mile of former NS track.  The Manheim Industrial is a division of East Penn Railroad, LLC. When NS couldn't give Ferrellgas the service they required, East Penn stepped in to handle switching of inbound lpg. A classic minimalist shortline.

Here is an Aerial Photo

Ferrell is located on the former Cornwall RR. The former interchange with the RDG was just south in Manheim proper (where the wye is located). Today, a Norfolk Southern local shoves cars of lpg past the wye, dropping them north of E. Steigel Street. East Penn uses a trackmobile to drill loads and empties in and out of Ferrell. Up to 9 or 10 cars may be dropped by NS. Ferrell can unload three cars at a time, so switching gets complicated quickly!



Ferrell Gas siding, looking south down the main. NS Interchange is past the crossing ahead.




NS local shoving lpg loads onto the interchange.




Backing in loads to be dropped north of the wye. There were some neat trackside industrial buildings in Manheim, but they were all razed in 2006.




Picking up empties. View is looking north from E. Steigel Street.

Now let's travel from PA to MI to look at another small classic: the Lapeer Industrial Railroad. Owned by the Adrian & Blissfield, the Lapeer Industrial operates 1.34 miles of former GTW rails to serve a grain elevator and a manufacturer of adhesives. Here is an AIR PHOTO of the line, which branches off the GTW main near the Lapeer Amtrak station. Note how all switches are trailing point, so there is no need for a runaround. Click HERE for an interesting article about the railroad.

UPGRADING TRUCKS UNDER WEAVER BOXCARS

This weekend I switched gears from layout construction to freight car upgrades.  A change of pace is always good!

I decided to upgrade the trucks on my Weaver 50-foot boxcars.  These cars look great when weathered and detailed! 

 

One downer, however, is that the Weaver trucks do not have rotating roller bearing caps.  Being a railroader, when I see a moving car with frozen bearings my first thought is that someone left a tight handbrake on!  To remedy this problem, I decided to upgrade the cars using Lionel trucks and NWSL wheelsets.  The conversion is very easy and simply involves flipping the carfloor.  The Lionel trucks are built differently than Weaver's.  Inverting the floor gives a flush mounting surface for the Lionel's.  It just so happens that the resulting car and coupler height are dead-on the NMRA height gauge.  No extra shimming is necessary. 

I began by disassembling the car:

 

Then, I cut the bolsters from the center sill using a razor saw.  I made sure to remove enough of the sill to allow the trucks to swing freely:

 

The ribbed side of the carfloor becomes the bottom; the smooth side becomes the top.  I add small blocks of styrene over the truck mounting holes (see top of photo below).  The styrene, when drilled and tapped, gives the mounting screws a little more bite.  I drilled and tapped for 10-32 machine screws, then reattached the underframe assembly to the ribbed side of the car floor with ACC.  Last was adding Kadee couplers and installing the trucks. 

 

I insert 4mm lengths of 0.093 diameter styrene into the coupler spring to eliminate the caterpillar-like effect of the Kadee's.  There is just enough slack action to create a realistic effect, while the coupler still moves side to side freely.