Cowra - Construction, December 2025
12mm thick plywood was purchased, with some ordered pre-cut into 50mm and 100mm wide strips.
In 2025 work began on our Group's new exhibition layout.
Modules were constructed from 12mm thick ply using our tried-and-true ladder style construction that has worked well for us on previous layouts. Four modules have been constructed so far: two modules for the front sceniced part of the layout and two modules for the rear storage tracks. Each module measures 2200mm long x 730mm wide, designed to fit into the Group's existing trailer for transportation. Prior to assembly 20mm and 50mm diameter holes were cut into each intermediate cross member to reduce overall module weight and to allow spaces for wiring to pass through later on.
Ladder frame module construction as viewed from below. The 50mm wide strips on either side are runners to facilitate getting the modules in and out of the train trailer.
In each module end cross member an elongated hole was cut centrally as space for hand holds when lifting and moving the modules. Holes were also cut each side to allow for the over-centre clamps which securely hold modules together. 12mm ply strips 50mm wide were screwed to the underside, to act as runners for sliding the modules in and out of the trailer, and for reinforcement to make an L-section of timber with the sides.
Plywood sheet was cut and fixed to the top of each module to be used as baseboards for trackwork. These also provide additional bracing for each of the modules.
Plywood top forming the base board roughly cut out and glued and screwed to the frame.
Each pair of modules were clamped together end-to-end and aligned. In order for the baseboards and track to align perfectly each time, custom baseboard alignment pins were sourced from ControlIt. The alignment pins are very simple to install - drill a 10mm hole, insert each alignment half into the holes, and screw into place. A drill guide was used to ensure a perpendicular hole to the module ends.
Custom baseboard alignment pins from ControlIt, made from hard and stainless steel and finished to industrial-grade tolerances. The result is an easy to install and flush fit alignment system.
Once aligned, the over centre clamps were fixed into place and adjusted.
Two modules clamped together and over centre clamps installed on square timber blocks.
Two front scenery modules sitting slightly apart showing the ControlIt baseboard alignment pins and an over centre clamp.
Each pair of modules is now framed and ready for the next stage of work.