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Top Deck Support on a Double-Deck Layout
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On a past model railroad club we had a free standing sectional layout with two decks. The layout was mounted on castered cabinets in sections up to 18 feet long designed to move from location to location. The curved sections tilted 90 degrees down into the cabinets so to pass through a standard doorway. The over all weight was a consideration. To keep this down we used the following for the top deck. <br />The central spine for the straight sections was 3/4 inch plywood which extended down into the cabinets. The curves were made from two sheets 1/16 inch plywood glued back to back. This created a very strong curved spine support. <br />The top decks two to three foot wide over hang, was supported on 2 inch wide vertical strips of 1/2 plywood. The two inch strips were notched one inch deep for the thickness of the spine where they crossed the spine. One inch square by 2 inch long wood blocks were screwed at the joints to the spine to re-inforce and stiffen the connection. <br />When the 1/2 inch plywood decking was screwed to the top of the plywood risers using more one inch square wood blocks the whole deck became quite stiff and solid. <br />The inside of a curve on the lower level was left open when the upper deck spaned a 6 foot gap using the same 2 inch by 1/2 inch plywood stringers and cross beams forming a box beam with the plywood deck. The two long stringers were notched over the central spine at each end to keep the curve in shape. <br />The finished deck was 3 inches thick and concealed lighting and wiring harnesses very well and did not detract from the viewing of the upper and lower decks. <br />If you are planning to get up and walk on your top deck by all means build it securely and solidly. <br />If the only use for the top deck is to support model trains then it does not need massive structural engineering. Ever built a balsawood airplane and noticed how stiff and strong all that thin wood became? <br /> All parts of the deck would be reachable from the aisle and not need to support the weight of the builder.
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