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#6 Left Hand Single Crossover

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#6 Left Hand Crossover

Construction – 40 pts

The #6 left hand crossover was scratch built in Z scale. The crossover was constructed using a "Fast Tracks" turnout jig and frog-point jig. The PC ties were placed in the turnout jig first and the various rails were soldered to the PC ties. The construction was complex because of the 10 – 12 steps for each of the two turnouts of the construction process. Then the two turnouts were joined and aligned to make a crossover. The main complexity was however, the very close tolerances and alignment that must be maintained for good operation at Z scale. Another complexity was to synchronize two opposite operating turnout controls using a single Tortoise machine.

The crossover was mounted on a mini-layout constructed of precision cut poplar board. After the mini-layout was constructed 1/16" basswood was used to raise the cork and track above the surrounding terrain. Ballast and track details were added to the mini-layout.

 

Detail – 20 pts

The Z scale crossover was made up of forty six (46) individual pieces of code 55 rail, pc ties, wood ties and wire. Several turnouts and crossovers were constructed and abandoned before the construction process was worked out. Difficulty arose in getting the very close tolerances accomplished so that operation was smooth. The rail and ties were initially painted Weathered Black. After the turnout and related hand laid rail and ties were glued to the cork roadbed a coat of "Weathered Black" was painted on the rail sides to create a used appearance. Along both sides of the crossover and related hand laid track is a drain ditch found in most prototypical trackage. The wood tie spacing is 22 scale inches on the branch line. A random assortment of ground foam was used to give some context to the mini-layout. Also adding to the context of the turnout is a mile marker (gray with mile "753") and an underground cable marker (orange). Splotches of discoloration along and between the tracks were added to mimic oil and grease spills of a prototype. Fine gray ballast was selected for the model. It was observed that in the Dallas area gray, brown and white ballast can be found. In the area where my main layout is to be modeled after, gray and white ballast is prevalent.

The track diagram is shown below.

               

The wiring diagram is shown below. Note that there are two power sources. One supplies variable voltage and polarity for locomotive power and the other supplies direct current battery voltage to operate the turnout motor.

               

 

Conformity – 30 pts

The Z Scale crossover was constructed using a jig that conforms to NMRA turnout standards. The wood ties on the related track are sized according to prototypical ties. Tie spacing is 22 scale inches on center for the branch line. The rail tops are shiny to suggest frequent use and the sides of the rail are a rusty finish to suggest the typical rusting that takes place after only a short time in everyday weather. Gray ballasting was used to conform to the track at the Inwood Yard in Far North Dallas. Drain ditches are present to symbolize typical track drainage. The switch stand, mile marker and underground cable marker are prototypical in height, distance from track and color. Reference photos are in the project binder.

Finishing and Lettering – 10 pts

The Z scale crossover was constructed from un-weathered code 55 stock rails, pc ties soldered to the rail and wood ties glued to the rail. The crossover was finished with a coat of Weathered Black then a special brown color mix was applied to the rail sides to create a rust look on the rails. The gray ballast finishes the general turnout appearance as well as the variety of ground foam to round out the context of the model. The switch stand is set up as a siding (or minor) switch stand and thus has a yellow although very weathered diamond shaped flag.

 

Scratch Building – 25 pts

The Z scale crossover is hand laid using a jig to hold the rails and pc ties at the correct gauge and bend. Although commercial jigs were used, cutting, bending and soldering techniques were very important to making the hand laid turnout construction possible. The frogs were constructed using a frog-point jig. Two pieces of rail were soldered together in a jig to make a #6 frog for the turnouts used in making the crossover. The related track was hand laid using code 55 rail stock and hand cut wood ties. The hand applied ballast was applied very sparingly since at Z scale a single grain of ballast can ruin a Z scale locomotive.

List of Materials (all parts are exempt)

A. Turnout (2 each)

2 – Micro Engineering Code 55 Stock rails

2 – Micro Engineering Code 55 Frog Point rails

2 – Micro Engineering Code 55 Closure rails

2 – Micro Engineering Code 55 Guard rails

10 – Fast Tracks PC Board Ties

1 – Lot Fast Tracks Rosin Core Solder – 0.003" dia

1 – Lot Acid Flux

1 – 18" Green wire #26 stranded – cut to length

2 – 18" Red wire #26 stranded – cut to length

2 – 18" Black wire #26 stranded – cut to length

Mini-Layout

1 - ½" X 6" x 24" Poplar wood board

2 – ½" x 4" x 12" Poplar wood board

2 – ½" x ¾" x 5-1/2" Poplar wood board

1- Lot Testors "Green" glue

3 – 1/16" x 2" x24" Basswood

1 – Lot IBL Cork Road Bed

8 – ¾" Sheetrock screws

1 – Circuitron Tortoise switch machine

2 – Circuitron Remote Tortoise switch mount

1 – 12 position terminal board

2 – 18" Green wire #26 stranded – cut to length

6 – 18" Red wire #26 stranded – cut to length

6 – 18" Black wire #26 stranded – cut to length

1 – 18" White wire #26 stranded – cut to length

1 – 18" Gray wire #26 stranded – cut to length

1 – 18" Red/Black zip Cord with Molex connector & pins/sockets

1 – Battery pack with "AA" batteries, holder and wire clip

1 – Frog Throw Switch

1 – Lot various Woodland Scenic ground covers

1 – Lot Half-Half white glue & water

2 – Evergreen #218 - .020" diameter styrene rod (Underground Marker)

2 – Lot Polly Scale GTW Morency Orange (Underground Marker)

4 – Evergreen #240 - .040" diameter styrene half-round rod (Switch Stand)

4 – Evergreen #102 - .010" x .040" styrene strip (Switch Stand)

2 – Evergreen #103 - .010" x .060" styrene strip (Switch Stand)

2 – Lot Polly Scale Railbox Yellow mixed with Polly Scale E/L Gray (Switch Stand)

2 – Lot Floquil Weathered Black (Switch Stand)

2 – Lot Poly Scale E/L Gray (Mile Marker)

2 – Reduced digital photo image of mile "753"

8 – Micro Engineering Code 55 Stock rails

2 – Yellow bumpers

2 – Orange bumpers

360 – Wood ties (hand cut to correct length)

1 – Lot Woodland Scenics #B75 Fine Gray Ballast

1 – Lot various ground foam by Woodland Scenics