Story of the BNSF Desert & Sierra Sub : from a diorama to a layout

[Frenchie]

Hello everybody and welcome aboard.

The construction of a 4 modules diorama representing Cajon pass Sullivan's Curve back in 1992 (see section "introduce yourself") was the beginning
of a great adventure.
This diorama was a "première" for me at the time and a real challenge.
I realized that the original ATSF 10° north track curve translated to 195cm (77") radius in HO. WOW ! Using "selective compression" I chose a more
decent 110cm (43") which I found impressive enough. It was built for shows and I didn't want to rent a tractor-trailor.
I used the same compression for the rock formations.

I attach some 33 years old photos showing a plan and some building steps. I scanned them, so sorry for the poor quality.
-Diorama plan
-Main module : styrofoam and plaster steps.

 

[Frenchie]

The addition of the train room after my retirement (2011) was followed by a long period of scale plans drawings, choices and finally
decisions.
In spring 2012, I knew it would be a 2 levels layout (almost 3), depicting a secondary ATSF, now BNSF line, with trackage rights to UP.
It represents a line climbing the eastern slope of a range from desert to a mountain pass.
Along the way trains wind their way through desert, canyons and sierra landscapes. Slow and heavy trains grinding up and snaking through
scenic scenes are, for me, the ultimate thrill.

The BNSF "Desert & Sierra Sub" also called "the southwest scenic route" is a "could have been" ATSF/BNSF line situated somewhere in the
southwest.

After a long and lonely journey westbound trains appear on the scene at the lower level and stop at the tiny hamlet named "Yaqui Wells" in
order to add necessary helpers for the climb to a high sierra passage : "Dog Soldier Pass".
At summit helpers come off their train and either return downhill for their next assignment, or wait for heavy eastbounds to help them
with braking power for their downgrade trip.
Westbounds then disappear from the scene entering snowsheds at West Summit.
Eventhough it's a scenic, main line oriented layout, there will be a (very) few switching spots. Beside the main line traffic, the continuous
ballet of helpers between Yaqui Wells and Dog Soldier Pass, plus the once in a while stops at Sandy Flats for refuelling, is more than enough
traffic fo a lonely operator, even for two.
I also plan an eastbound morning and westbound evening Amtrak "Desert Chief" so passengers will enjoy the surrounding scenery.

There are 2 hidden return loops, representing eastern destinations at the lower level. A single top level hidden return loop represents western destinations.
A continuous route connects both ends of the layout by way of a hidden but accessible helix. I wanted trains with open cars, coal for example,
to always run in the same direction : full westbound, empties eastbound.
Return loops are for "waiting to come back" locals or for Amtrak passenger trains.

Now the rules I imposed on myself :

- Minimum visible radius : 90cm (36") - Hidden : 80cm (31.5").
- Helix radius : 84cm (33").
- Turnouts : minimum n°6, n°8 on main - n°7 curved.
- Maximum grade : 3% (there is a short 3.4% stretch).
- Helix grade : 2.2%.
- Track code 83, bulk code 75 for guardrails.
- Curved backdrop everywhere.
- Lightning : 5 watts LED spots, 100° light angle, colour temperature : 4000 Kelvin (it isn't too cold, neither too yellow).

I'll be back soon.

 

[Frenchie]

Before getting any further, I send plans of the different levels. The layout is freelance with some "real life scenes" mixed in...

- Plan 1 : portion of the lower level.
- Plan 2 : portion of the upper level, above plan 1.
- Plan 3 : other portion of the upper level.
- Plan 5 : other portion of plan 1.
- Plan 4 : upper level reverse loop, underneath n° 3.

I hope those plans will be clear enough which is not necessarily obvious.

 

[Frenchie]

I build the layout like a series of dioramas placed end to end. When the first is completed except for tracks at both ends, I build the next one
west or east and I connect them together, completing the track job and hiding the joints between dioramas with scenery.
I progress so, step by step, knowing I won't have to go back except to improve some small areas.

Whenever I can I like to use sawhorses, so I can work from all directions before installation. But as the construction progresses there is less
and less room to work, so I give up the sawhorses and manage differently.

Step 1 : Drawing the diorama to scale ( 4 cm on the plan equals 1 meter ). To be adapted in inches.
Step 2 : Building a wooden grid, I use 2 x 4 cm slats.
Step 3 : Installing a 10 mm thick plywood fascia on the future aisle side, sometimes on 3 sides. I cut the top of that fascia to the contour of the terrain I want to create, what I call thinking ahead in 3D.
Step 4 : Installing risers then the subroadbed (18 mm plywood ) cut and installed according to my drawings.
Step 5 : Piling and gluing styrofoam on the grid, slabs are also glued together.
Step 6 : Using an old rasp in order to make the styrofoam terrain match with the fascia top outline.
Step 7 : Gluing more styrofoam pieces where I want future rock formations. Roughly shaping them with the rasp.
Step 8 : Using basic SLOW SETTING construction plaster ( 40 pounds bag last for a while ) to create rock formations.
Step 9 : Hand carving the plaster, usually about 8 or 9 hours after application, depending on the batch, temperature and air moisture.
Step 10 : Spreading glue on the carved foam terrain and "pouring" screened sand and stones.
Step 11 : Wetting the terrain with alcohol or "wet water", than again with a 50/50 mix of glue and water plus drops of detergent.
Step 12 : Coloring rocks with gouache (water colours) and terrain with an airbrush. Darkening areas with india ink then drybrushing the terrain
and the rocks.
Step 13 : Masking screw holes and painting the fascia.

These are the steps I follow and it works well.

 

[Frenchie]

Photos of the very beginning (spring 2012) :

- Home made brackets to support my Sullivan's curve diorama.
- First installation, later on the fascia will be painted a dark chocolate colour to replace the aging sandy buff you can see.
- The definitely installed diorama.

When properly installed, I removed the track and ballast and installed new track spanning the joints between the modules, then covering
the same joints with scenery and reballasting.

 

[Frenchie]

Hello !
A word about the photos, when checking "Image Metadata" - "Date Taken", the indicated date, 01 January 2000, is wrong.

The reason : My mistake, I never set the date on my camera, so you'll find out that all my photos show the same date.
This remark to avoid any confusion. Frenchie.

 

[Frenchie]

With the diorama installed the time has come to start the layout construction.

From the start I very well knew that I had no intention to build a scale model of famous Cajon pass. I cannot fill a room with the same
kind of scenery, I get bored very quickly.
I like scenery variety and the challenge to blend everything logically to end up with a believable miniature geology. These are the reasons
that led me to build a model railroad with freelance scenery and inserting some prototype scenes in the mix.
It might seem weird, I call it modeler's license.

Starting at the diorama, I began construction westbound (left). That first portion being 2 meters (79") long (Plan 2).

25 and 28 : Testing the diorama installation.
31 : Note the slight winding nature of the subroadbed in order to get a more interesting effect.
34 : The new portion ready for the "rasping step".
39 : Future "Rainbow cut".
43 : "Hoodoo wash" almost completed.

 

[Frenchie]

Photo 31 shows the already installed fascia on the future aisle side. Later on I shortened the high portion visible toward the rear,
to better match my idea of the future scenery. I also cut a portion of the subroadbed to accomodate the short bridge spanning Hoodoo wash.

Since I have hundreds of photos, I send now some of the completed new section.

- 481 : A westbound emerges from the cut just west of Sullivan's curve.
- 64 : Early photo showing how the lower strata on the left matches those at Sullivan's curve, colour and angle, the idea is a "geologically logical"
landscape. Yeah I know...
- 155/156 : Rainbow cut and the bridge spanning Hoodoo wash.
- 160 : Rainbow cut, different angle.
- 205 : Another angle.
- 207 : West of the wash.
- 380 : Closer rock view.
- 104 : Note the swallows nests in the cracks between stratas.

 

[Frenchie]

Hereunder 2 more views of the now completed section.

The small "mesa" to the rear of 221 is carved styrofoam, a technical I wanted to test.

 

[Frenchie]

Progressing west the next diorama proved to be very challenging. Located in a corner of the room. A 150 cm (59") side and a 250 cm (98.5")
rear side. (Plan 2).
The good thing was I could manage a spectacular 135 cm (53") radius curve surrounded by impressive scenery, big "mesas", balancing rock,
an arch and testing my skills with a road in "forced perspective", an old dream never realized before.

- 105 /106 : Testing placement at the wooden grid step.
- 110/111 : Fascia added.
- 112/113 : Subroadbed installed with room for a future bridge.

 

[Frenchie]

Back on the sawhorses in order to have full access for the next steps :

Foam, plaster and so on.

- 118 : Some of my plans and sketches.
- 119/123 : Styrofoam step, first glimpse at the forced perspective road which I installed across the widest part of the diorama for maximum effect.
The road is exact scale width at the fascia, slightly narrower at the grade crossing, then diminishing quicker in width toward the "horizon".
- 129 : First foam carved "mesa".
- 132/134 : Testing mesas placement.

 

[Frenchie]

- 140 : Future "Standing rock gap".
- 142 : Carved foam mesa including the arch baptized "Looking eye".
- 144 : Detail of completed carving and coloring.
- 165 : "Mesas" temporarily installed. They are so light they can be moved to the side before final installation, after hanging the diorama to walls.
- 168 : Working on the "forced perspective", note the rollercoaster shape of the road for a greater look.
- 169 : More plaster rocks in order to reduce the viewing angle of the perspective, otherwise the wanted effect would be ruined.

 

[Frenchie]

- 171 : "Looking eye" arch.
- 173 : Plaster rocks in the front, styrofoam in the background.
- 179 : Vestiges of the original trestle which carried the old narrow gauge, first line to conquer the sierra.
- 182 : Many years ago a late friend kindly gave me this building. I installed it and added a lot of weathering plus several details around it.
- 213/210 : Building a bridge over dry "Diamond back lake". Abutments and pier are plaster of Paris.

 

[Frenchie]

- 222 : Part of what's called "Painted mesa".
- 371 : The bridge spanning dry "Diamond back lake". Behind is the entrance of "Spaniard canyon".
- 368 : Another viewing angle.
- 426 : Santa Fe westbound grinds its way upgrade cutting US 38 beside Standing rock gap.
- 378 : The nearby "tourist trap".
- 609 : Latest acquisition to attract the passing by tourists.

 

[Frenchie]

- 377 : Blooming yucca.
- 424 : The forced perspective : there is only 82 cm (32.5") from the fascia to the sky backdrop. The all plan was calculated so the road top is
slightly below my own eyes level while standing relax. This way the effect is maximum.
- 793 : There ends, for now, the upper level westbound progression.

 

[Frenchie]

- 430 : Ocotillos and yuccas.
- 432/925 : Views of the "tourist trap" area.
- 400/418/420 : Your choice, dusk or dawn. A LED strip is installed along the rear of the diorama.

 

[flyboy2610]

That's very impressive! Quite a project you have going on there!
I have to make it until Nov. 1, 2028 until I retire.... provided I can stand it that long.

 

[Frenchie]

That's very impressive! Quite a project you have going on there!
I have to make it until Nov. 1, 2028 until I retire.... provided I can stand it that long.

Thank's flyboy 2610, it has been a long and fantastic journey. Sincerely I never thought I would live long enough to see the layout completed.

13 years ! I have done everything on my own, the advantage : it is and it was done the way I wanted, I could only blame myself for the errors
made. I also learnt so much on myself when I had to solve the thousands of problems I encountered along the way.

Building completed dioramas one at a time is a very slow progression and a discipline, it is not always accepted, usually people want trains
running as soon as possible. The way I chose avoid to look back at 50 or 100 feet of tracks waiting for scenery, It must be daunting if not
frightening.

But thank's god, a layout is never finished, there are always things to improve scenically and technically. Actually the big highway bridge
spanning the river and the railroad in Dead horse canyon (plan 5) is not built yet. That's another challenging project lying ahead.

It's already late here (jetlag), so I'll see you tomorrow folks.

 

[Frenchie]

Hello everybody.
I decided go back to Sullivan's curve diorama and, this time, progress eastbound (right). (plan 2).

In order to progress toward the room center, I installed vertical posts reinforced horizontally at their tops and feet. The ceiling being
assembled synthetic slats with 15 cm (6") insulation on top, there is no possibilites to fix anything to it.

Now it's time to start progressing east.

- 279 : The first section. The end closest to the camera will be the interface with the Sullivan's curve diorama. Note the "stepped" frame to
accomodate the 3% downgrade to the right.
- 281 : Testing the location.
- 311/312 : Foam carving/rasping step.
- 314 : Making molds for the future tunnel portals. The visible pipe (311), marks the future "yucca wash" location.
- 317 : Plaster of Paris portals gently drying. Inspiration came from those which once stood at Alray (Cajon pass).

 

[Frenchie]

- 318 : Buiding the tunnel quickly became a challenging puzzle.
- 331 : A piece of weathered and ballasted track was installed in order to complete the tunnel. This is the east portal.
- 335 : Foam step completed, this is the west portal. Right is the aisle side.
- 343/346 : Carved plaster step completed.
- 442 : Scenery around west portal. Yucca wash in the foreground.