Following the events chronicled in the first post on my model railway projects, I made a trip to our nearest Jewson store in search of a sheet of plywood and two lengths of 2-by-1 timber. Unfortunately they did not have birch ply, which my internet searches indicated was the recommended material for model railway baseboard surfaces. They did have sheets of ply the size I was after (2ft by 4ft) though so I purchased one along with the 2-by-1 timber which they cut into two lengths for me.
Back at home, work continued on the baseboard legs. I cannot remember the exact sequence of events, but each of the tasks undertaken will be covered here (just not necessarily in the correct order).
Somebody had found me some bolts to attach the legs, so four holes (one for each corner of the baseboard) were drilled to accept the bolts. As with the legs, the timer of the framework was rather hard; each hole took a while to drill and required a fair amount of pressure. The result of this was the drill would jump forward dramatically once it was finally through, hitting the internal bracing of the framework and causing me some alarm that the strength of the structure might be compromised. Fortunately the damage was minor and I was reassured that it was not a problem.
After some measurements, I made a notch a short distance from each end of the two new lengths of 2-by-1 softwood timber. This was done by sawing roughly halfway through the timber and chiselling out the wood in between. The cutting was much easier than the old timber, and I doubt I would have been able to chisel it by hand as I did with the new stuff. These two lengths were then used to hold the base of the legs apart, with the notches slotting over the lower horizontal brace of the leg assemblies. At some point (probably before the notches were cut) it was noticed that these horizontals were not the same height above the ground, so one had to be moved to correct this so that the new spacers could work. Even now however, the table still wobbles slightly, though my idea of the new notched lengths of timber seems to help.
I got out some track and had a play to make sure the layout I had in mind would fit. Interestingly, the arrangement I came up with was different from the plans I had created using layout planning software, so I recorded the plan (in the layout-planning program SCARM) before packing the track away.
The ply sheet was varnished, both sides, and measurements were made in an attempt to get the ply centred on the framework (the framework is slightly smaller than the ply sheet). Eventually it was pinned onto the framework using about 12 pins around the edges. I may have got the ply slightly off centre, despite all the measuring, but I’m happy enough.