Our First Z-Scale Train Layout
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Chronology of Our First Z-Scale Layout
This is the story of our first Z-Scale train layout. It all started with our trip to the California State Railroad Museum in November 2009. It was there that we saw our first Z-Scale trains, and were immediately hooked. Z-Scale is very small - 220:1, and is perfect for people like us who have limited space but still want a layout with lots of detail. Over the last two-plus years we have collected Z-Scale locomotives, rolling stock, buildings (some of which we built), scenery and supplies. The locomotive pictured is our first - an AZL Norfolk Southern SD70, and the AZL Norfolk Southern caboose is our latest addition. After lots of thought, we decided on a plan for our first layout. We had purchased a Marklin layout book and picked one of the plans we found in it. We then began to gather all the parts and supplies we would need. Our main source was EBay, and It was like a treasure hunt. Once we had all the parts assembled we had to decide what type of material we would use for the base of our layout. We settled on gator board and purchased a piece big enough to fit our layout. When we finally finished gathering all the parts and supplies we would need we were ready for the fun to begin. Almost two years to the day that we visited the train museum we got started. The following is a chronicle of our journey.
The Inspiration For Our Layout
For our first layout, we wanted something more than a small oval (where's the fun in that)! So we looked through some Marklin books (Marklin is the German manufacturer that launched Z-Scale model railroading in the 1970s) and came up with the largest track plan that we could fit in our limited space - roughly 30" by 50". For beginners, it's a pretty ambitious plan that has 12 turnouts, 3 signal lights, 3 uncoupling tracks, a locomotive storage building and the ability to add two catenary lines (overhead electrical wires). It can use up to four separate power packs and a host of switches. Once it is done it can run up to four trains at once. Fun!
To make life easier on us, the layout is basically flat, so the landscaping should be simpler - adding roads, ground cover and buildings as opposed to hills and mountains. There is a raised bridge on the back end of the layout that adds some elevation interest.
Since we want our layout to be as portable as possible, we decided to use foam-type materials as opposed to plywood for the base. Woodland Scenics manufactures a variety of thicknesses of foam board for this purpose, but nothing big enough for what we wanted to do. So, for the base we decided to use a product called "Gator Board," which is basically foam sandwiched between outer layers of wood-fiber. It is very light and very strong - perfect for what we are trying to do. Our plan is to cover the Gator Board with a 1/2" layer of Woodland Scenics foam on top (this will give us some flexibility in doing our scenery, while retaining the integrity of the base). We also plan to make a frame of foam strips on the bottom of the Gator Board to allow us to run the copious electrical wiring down to the underside of the board and keep it as out of sight as possible.
Of course, we will take "artisitic license" with the final design. In other words, our layout will look different than what you see in the picture.
Whew, wish us luck!!
October 28, 2011
Step One - Cutting Foam
Today we started our layout! Actually, we started a long time ago, with the planning and purchasing. But today, we took the foam cutter out of the package and cut six 2-inch X 24-inch strips from foam board with the intention of attaching them to the bottom of our gator board to act as a frame. We used the hot foam knife. Very interesting to use! It cuts well, but you do lose some of the foam because of the heat. 
Amazon
November 5, 2011
Step Two - Gluing The Frame
Today we took the six pieces of foam we cut last week and the remaining piece and attached them to our Gator Board with the glue gun. We realized that if we tried to apply the glue to the underside of the foam or directly to the Gator Board it would dry too fast. So Gary's idea was to glue around the edges, and this worked very well. He did the first one, then we alternated, and he finished by doing the middle strip. We spread two old tablecloths in the garage and worked there. It was a cold, rainy day, and the Cal Bears (our alma mater) beat WSU in football at AT&T park. Glue gun glue comes in sticks. We used one short stick of glue, all of a long one, and part of a second long one. The foam seems to be on quite securely 
Amazon
November 13, 2011
Step Three - Attaching Distributor Plates
Today we brought out the big gun - the jigsaw! Earlier in the week Gary bought a piece of 1/4-inch plywood at Michael's (craft store) and came up with the idea of cutting out small pieces of wood to attach to the distributor plates so that they, in turn, could be attached to the bottom of the Gator Board. The distributor plates are where the electrical wiring will be connected to. We used the jigsaw to make the cuts. Gary did the first cuts and cut out two pieces. I did the next two, and Gary did the last ones (we need five, but cut out six). It was quite amazing for me to use a jigsaw for the first time. I "channeled my inner NIcholas" and thought of my late little brother and his power tools and woodworking. Miss him. After successfully cutting out the wood we screwed the distributor plates to the wood using the screws we bought at Lowe's yesterday after picking up more 1/2-inch foam board at "Just Trains" (our local model train store). Gary did three of them and I did two of them. Then we got our Gator Board out, fired up the glue gun, got out the plan, figured out the placement of the distributor plates (being careful to remember that the board was upside down, so the placement would be opposite of the picture) and glued them in place using the same method we did with the foam, i.e. gluing around the edges. The hold is extremely sturdy, but we would be able to take the wood off easily if need be. The day was cool, but bright and sunny. Perfect day for working on our layout! 
Great Stuff on Amazon
November 20, 2011
Step Four - More Foam Cutting and Gluing
On Sunday, November 20 we moved back out to the garage, and used our Foam Tack Glue for the first time. The plan was to cover the top of the Gator Board with a layer of 1/2" thick foam. After cutting off the tip to open it and finding a straight edge to use for spreading it, we started in. Gary did the first gluing - squeezing the glue out in a grid and then spreading it. Then I did some, and the then we worked assembly-line fashion, Gary squeezing out the glue, and me spreading it. We thought we might have a bit of over-hang on one end, but, if so, it's very little, and if it proves to be a problem we can sand it down a bit. We placed all the foam pieces as we went along, and then left them to dry. We are almost ready to lay track bed!
November 27, 2011
Step Five - Placing The Track Bed
eBay
December 10, 2011
Step Six - Gluing The Remaining Track Bed
eBay
January 1, 2012
Step Seven - Making Some Repairs
New Year's Day! We brought out our layout and considered the problem of some of the track bed not sticking securely to the foam board. We tried prying it up from the edges, but were worried about ripping it or otherwise damaging it. Gary had the idea of cutting it near the problem areas, and that is what we did. Gary used an X-acto knife to make some cuts, and then he shoved glue under the track bed and spread it with a knife. After this we weighted it with books and some of Gary's dad's old scale weights. In all we made three cuts and filled four problematic areas. Now we wait. Hope this works! (Update - the fix seemed to work OK).
January 7, 2012
Step Eight - Experimenting
Today we experimented with drilling through the different layers - track bed, foam board and Gator Board. We wanted to make sure we would be able to run the wires through from the top of the layout to the bottom of the base. A little ice-pick implement worked perfectly for drilling holes in the boards. It was a little hard to run the wire straight through on its own, but we used a thick darning needle, and it went through easily. Success! We also looked at the Marklin track nails to try to determine if we would be able to hold down the track just with the nails, and not have to use glue. After the experiment, we are hopeful this will work. January 14-15, 2012
Step Nine - Attaching The Track
eBay
January 28, 2012
Step Ten - Continuing with Attaching the Track
On Saturday I was feeling a bit under the weather, but we forged ahead with completing the laying of the track. I did participate by hammering one of the nails. We wondered if we could get some gold paint and paint a little nail to be our "golden spike" when we finish. It was really cool to see one of the original Golden Spikes at the Train Museum in Sacramento. While I took it easy (except for my turn with the hammer and spike) Gary finished laying all the track except for the bridge. For that we will wait for the wiring to go in. And, speaking of wiring, it looks like we are almost ready to start tackling that part of our layout. That promises to be a big challenge! 
February 4, 2012
Step Eleven - Starting the Wiring
Today was a red-letter day. We started the wiring! We have always known that this will be a major challenge. Our layout has twelve turnouts, three uncoupling tracks, three train signals and a locomotive shed. There is going to be a lot of wiring! But, you have to start somewhere, and Gary took the plunge (literally) by pushing a punch tool through our layout board and creating the first hole for the wiring. We alternated working on the wiring with watching the Cal Bears beat Arizona State in basketball (Go Bears!). I'm very glad that Gary understands wiring because I sure don't. I'm learning, though, although for this stage I am definitely more of a helper than participant. Gary cut and stripped the wires, poked the holes, pushed the wires through, attached them with clips to the bottom of the board, and bound the wires together. As for me, I tried my hand with the wire strippers, and helped to hold up the board. Once we got to a certain point, we put the layout away for the day. There is going to be a lot of wiring when this is all done. It will be spaghetti! This is so fun! Our layout is really starting to shape up! 
More To Come
Check back periodically as we continue our Z-Scale Layout adventure!
Next up - the wiring heats up!
Some Alternate Destinations
While you wait for the next installment in our odyssey, why not make tracks to some of our other Squidoo lenses?
All Aboard With Your Comments!
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karmicchristian
Jan 30, 2012 @ 7:11 am | delete
- Sounds like a very interesting and a painstaking adventure! Best wishes on your project!
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flycatcher
Jan 29, 2012 @ 7:26 pm | delete
- That just looks like so much fun - heaps of work, of course, but the fun kind of work. :) Great job!
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CruiseReady Jan 27, 2012 @ 7:43 am | delete
- Wow - such a long and painstaking - and beautifully documented - process~
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stuhaynes
Jan 27, 2012 @ 6:05 am | delete
- Great fun!
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WriterJanis
Jan 26, 2012 @ 2:31 am | delete
- I want to come over to your house to play!
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by APackageAtTheDoor
We are two grown-up kids who love our toys! We grew up in the 60's when kids saved cereal box tops to order cool stuff (and our parents saved blue chi... more »
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