INTRODUCTION: This short guide and checklist should be used together with the GFG Standards while building a module. The checklist focuses mainly on the END PLATES and to a lesser extent on the electrical power wiring. It is the RESPONSIBILITY of the builder to arrange with the STANDARDS WORKING GROUP to have the new module checked and approved before taking part in the first module setup.
END PLATES: The checks below apply specifically to module end plates which join to other modules. It is good practice to also use applicable checks for “internal” module ends.
1. Only end plates supplied by GFG are to be used.
2. Minimum thickness is 12mm (laminating two end plates if necessary).
3. Module construction, including strengthening of end plates MUST provide enough space for bolts and washers and generous access for spanners.
4. End plates to be at EXACTLY 90 degrees to the module surface (carpenters square).
5. Track adjustment at the end of the module to be achieved by using the GFG TRACK GAUGE.
6. Track at the module end must be:
i. 90 degrees to the end plate
ii. Straight for at least 100mm
iii. Level for 100mm or more if possible
It is advisable to use wood, 100mm long, 40mm wide and 5mm thick to
provide the ballast shape. Thereafter cork or closed cell rubber should be
7. Track ends to be soldered to either:
i. Brass/brass plated flat top screws, or
ii. Electrically gapped and firmly fixed PC board
8. Track ends to be flush with the outer surface of the end plate. The inside of
the rails to be slightly champhored.
9. Module height standing on its legs and pads is 1200mm from the floor to the
top of the rails.
10, It is essential to bring a pair of spanners, matching the 10mm bolts (size 17
spanner) to each setup and breakdown.
ELECTRICAL POWER WIRING:
11. Each piece of track (however short) to have droppers to the two busbars.
12. The ideal droppers are single strand bare copper wires (+/- 0.7mm) unraveled
from uninsulated copper earth wire.
13. Droppers to be soldered to the track and the busbar (use bare earth copper wire.)
14. Wiring to follow the inside/outside track principal. Colour coding is not necessary.
15. Each module to have one pair of loose male/male banana plug jumpers (300-500mm long) per one module end. The female plugs to be fitted firmly at the end and near the edges of the module and connected to the two busbars.
16. Before installing points/switches check the point for electrical continuity using a multi-meter or the voltage indicator light built by Colin. There must be complete continuity in electrofrogs (gap in continuity for insul frogs) right through the point up to and including the two diverging legs
Note: Current Peco code 83 electrofrogs have a LIVE frog the polarity of which is switched by the switch blades. Electrofrog points require insulating fish plates for the two INNER rails after the frog.
17. Once all track and electrical wiring has been installed on the module and before “ballasting” and “scenecing” such a “bare” module must be used in a “set up” and allow trains to operate flawlessly across it. Once this has been achieved the module can be finished.