Batch making legs

Posted by Alan on 31st August 2015 in 0n30, Alan's Railway |

The modular boards didn’t come with sky hooks so I’m going to have to make five sets of legs, one more than the number of boards I have, so that I can set them up at home for working on it.

I have in mind a leg design that holds adjacent modules in alignment without using the bolt holes but it’s both untested and non compliant with the published standards. With the Seaboard Southern show now just over three weeks away, I’m going to copy Brian’s tried and tested version for the time being.

21m of 75mm by 25mm prepared timber was purchased from Dunwoodys in Caterham. Now here’s a tip; never go to a builders merchant on a Saturday or in the morning. Go after lunch during the week and you could get your cutting done for free. I asked for 10 lengths each of 2′ and 3’6″ so that I had stretchers and stiles.

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A visit to Brian’s one evening last week, to copy his design and use his chop saw, saw me leaving there with one assembled leg and four kits of pre-cut parts for assembly at home. The stiles were cut to 500mm, being the width of the module boards, which would have been more sensibly done at/by Dunwoodys.

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The legs were cut to put the top of the modules at 37″ above the floor when the feet were fully wound in. The feet we’re using have ±1″ adjustment. This height is way below the standard but, as it’s only us in the group at the moment, we’re working to a height that we’re more comfortable with. The legs can easily be lengthened later if we play trains with a standards-compliant group.

After five sets of legs were assembled, they were promptly taken apart again and, using my new router table, all edges were rounded over using a ¼” bit. This was so much easier quicker than using the router hand-held, as the long lengths could just be run through on the router, rather than having to be clamped down, and swapped over before the next could be attacked.

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As a proof of concept, here are the two corner boards bolted together as one unit and supported by a pair of legs. I’ve jammed it around the corner of the table as the bolts aren’t long enough to go through the legs. Time to go shopping again!

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