Developing Our New Track Site.


The need for a new Track.

Since 1988, the Society's third raised track operated in Sandringham Park, and served us well. But increases in vandalism and interference to the track and operation, noteably after an adjacent skateboard park opened, caused much extra maintenance, often involving repair by the same one or two people.

Sadly, this also detered some members from taking their locomotives to the track except during a week-day when most children were in school. During a weekend's steaming in 2005, some of the children to whom the railway was giving rides conspired to place items on the track, derailing Keith's locomotive, which sustained some damage.  As these miniature locomotives are the product of many thousands of hours' work, owner's reluctance to invite problems is understandable.

But contrastingly among our membership, now being drawn from a larger area, are many who are constructing new locomotives, and desire a safe track where they can be run. Other Society members own traction engines or steam rollers, and the membership voted to find a new location which would suit all our needs better.

Active Searching.

During 2004/5, Derek spearheaded the search for both funding and a more secure location, where we would be able to enjoy our hobby without mindless interference. Sites at Ipplepen, Dawlish Warren and even Exeter were given serious consideration, but all were eliminated.  In the Spring of 2005, three members of the Committee had a meeting with the Chief Executive of Teignbridge Council in our pursuit of a new location for our track and the need for operational safety.  The search was stepped up and a few more possibilities were identified.

In mid-summer, though shrouded in secrecy, a site was identified, land which the Council was in the process of buying to allow access to a huge culvert required for highways maintenance.  Since this area is potentially liable to flooding, and part of a water storage scheme, it is unsuitable for housing but fine for a raised railway.  Importantly for us, it's away from close proximity to housing, playing fields and skateboards.

Members of the Committee were consulted, and following a survey, Ron worked up a provisional track plan based on the demanding site gradients. This more private site would allow for an increased length railway track and a central traction engine arena.  Planning consent (for the whole scheme) was granted in mid November, and Contractors moved in to create an access road for Council maintenance vehicles, which we can also use.

First Moves.

The Contractor finished installing the initial stage of the access road by the beginning of December 2005.  Whilst the Tenancy agreement was being finalised, the Society pursued grants and other funds that might be available to us to create this facility, appropriate to the 200th anniversary of the birth of Brunel (2006), in an old railway town.

Track Layout.

The track was estimated at 960 feet length, and initially included two rail bridges to cross the water course adding interest, intended as opening sections to allow Council maintenance equipment to go inside the track area, to keep the culvert clear.  However, due to a number of factors, the Committee later decided on a slightly less ambitious scheme with a narrower track footprint, removing the need to cross the brook. The valley shaped site reqires a fair rise from one end of the site to the other, and will have some testing gradients.

Plans and Construction

The intention is to build a raised track, from new materials, dual gauged for 3½" and 5" gauge locomotives.  Included in the brief were steaming bays, with a trailer off-loading spur, serviced by a turntable. Also it was deemed a Club house would be essential (something we had never had), which would initially be used as a site office and materials storage.  A future bridge could cross the track to allow traction engines to drive to the arena in the central area.

A lot of thought went into trying to make the track easy and quick to construct, and without the need to mix mountains of concrete for pillars.  In the end it was agreed to use scale secion steel rail, screwed down to purpose made plastic sleepers, supported on twin longitudinal timber beams, in turn bolted to galvanised steel posts pushed into the ground, set in concrete where required.  We our grateful to a number of members who have donated the bulk of materials for the track construction.

Outlook

This is a brilliant opportunity for the Society, and co-incides with our highest ever membership level.  We have the potential for a fantastic track in a wonderful setting, which will serve for generations to come. The funding is pretty much in place, so now it's a case for pooling the enthusiasm that has been generated and getting stuck in !

Not a member yet ?  Still time to get involved and give us a hand - and get working on that new locomotive !

Our construction diary is in the next column . . .
Please hover your mouse over photos for a description.


Top finished.                     18th July 2008

Two further afternoons supported by Gordon, Maurice and Rob, allowed Geoff to finish the concrete top of the station platform, despite the miserable weather in late June and the early part of July.  The remaining tops, slopes and step consumed a tonne bag of aggregate in the concrete mix.  Meanwhile Dave sorted out 2 irritating slow punctures on the mower, now in regular use.

Ron has fitted the test track with buffer stops, the one at the turntable end can be discretely hinged over the end of the track to allow access to the turntable.  Hopefully this should prevent accidents with runaway locos while testing.  Also the site has been grass-cut, strimmed, and Dave has toiled to remove ragwort weeds that have invaded the the wilder parts of the site.

Meeting Steam Up !                     30th June 2008

In sharp contrast to May, the June meeting held at our new track was the first to have a loco in steam.  A good turnout, and many were able to ride the track for the first time as Pete steamed his pannier loco once again.  But no time for celebration yet, there is some work to do on correcting cambers and dips in the track; nevertheless this was deemed a succesful evening.

With the experience of the May club night flooding still freshly in mind, a small team got stuck in on the Satuday morning after the meeting to dig the remainder of a relief channel to stop water in the adjacent field building up and overflowing into our top cutting.  A few roots and other obstructions have also been removed to ensure the brook runs freely.

This followed the installation of six steaming bays, each provided with a 12v power supply.  The traverser is being temporarily re-used while a new one is made, suited to this site.  In time the adjacent area should be paved, the club was donated some large re-usable paving slabs, brought to site by Ted, Derek and James.

Ring of Steel Completed.                     18th June 2008

Having made fantastic progress with rail, fish-plates, countless sleepers, and even more screws - Dave & Ron completed laying our circuit of track, and the 'test spur' on 13th June, well over 1000 feet in just 5 part weeks - and it looks very good.


Our dynamic duo have also assembled and made ready for use a toilet in it's own housing, complete with light and ventilator - the first time the Club has been able to provide such a facility, which will be appreciated by many.  Work now turns to the steaming bays.

Behind the Scenes.                               8th June 2008

The May club meeting was the first in this year's calendar to be held at the track site.  In the 2 hours prior to the meeting, Newton Abbot saw some reasonably heavy rain, falling on saturated ground.  Those who ventured out to a sunny evening witnessed a sudden and unexpected flooding of the site's central area.  No track damage occurred, and we can now plan defences.

As track laying progressed, the first week of June was busy with lots of members involved; a start was made on a new flood prevention ditch, rail was prepared, sleepers moulded, rubble loaded, and water crane parts sourced.  On Saturday 7th, dodging some heavy lightning showers Geoff, Jeff, John and Rob added ends to the first platform, while Pete ran the mower around.

Clearance Testing.                               21st May 2008

The 4M turntable, one of the jewels of the track is now complete and ready for service.  Ron has designed an interlock to the various 'roads', operated from a centrally placed lever accessible from either side.  The length allows a loco + trolley to be turned, reducing delays on the mail-line.

By invitation, under the auspices of 'checking the clearances' Pete managed to get the first steam up on the part circuit.  Appropriately his loco '1761' is an original 'Newton Abbot' build, although it was sold and has travelled over the last 40 or so years, before coming into Pete's hands.  He reported that the gauge widening seems just right to allow free running on curves.

Beset by Water.                               18th May 2008

This week brought the worst thunder and lightning storm for many years locally, with torrential rain.  This took it's toll on our access road where cascading water carved many deep ruts.  But the additional rain on Friday night burst through from the adjacent field; a continuous flow of water entered and followed our top cutting, flooding over 1/3 of the sites.  A relief trench will be required urgently to divert this and future water away.

Meanwhile on Sunday, with Rob having built up the remaining rear station walls, and following a lot of rubble gathering, the first piece of platform top was poured; Alan mixed the concrete as new member Geoff poured and floated the new surface.


The Start of Track-Laying.                           8th May 2008

Clearly influenced by too many hours looking at Triang Hornby catalogues, Rob's station design capitalizes on the track height to include separate raised platforms.  Here Rob inched it closer to completion as the cut sloping ends were cemented onto the walls, and by adding the inner facing step base.  The voids now await filling with rubble before concrete tops can be poured.

On Saturday Ted delivered a batch of 300 sleepers, so track laying now commenced in earnest, the rails are being laid with staggered joints to minimise any kinking.  By the end of a hot Wednesday over 30M of track had been laid by Ron & Dave, virtually 1/10 of the total track length.  For this, battery powered screw-drivers, and spare re-chargeable batteries have proved essential.

Building the Platform Walls.                       4th May 2008

Following a very showery April, the first Saturday in May saw a small team assemble to build the platform walls.  With Jeff busy at the mixer, Alan and Geoff built up the block walls while John & Rob kept materials at the ready.  During the day John Bradley a model engineer visiting the U.K. from South Africa paid us a visit, he'd been following the track build on the web-site.  By 4.00 p.m. the bulk of the two block high outer walls were up.

Arrival of the Sleepers.                           30th April 2008

There was a huddle at the back of the April club meeting as Ted brought in the first batch of freshly minted sleepers, from his new injection moulding tool.  Long awaited, some delay was caused by finding the right material, polypropelyne was not sufficiently strong; and finally polycarbonate was chosen, giving a tremendously robust sleeper.  The wood grain effect sleepers have recesses and prepared screw holes to locate the flat bottomed steel rail, laid initially for 3.5" and 5" gauges, with the provision for 7¼" gauge rails to be added later.  The following Monday, Dave & Ron were building the first piece of track on the turntable; the finished result looks fantastic !

Platform Foundations.                               13th April 2008

A showery morning greeted Saturday's 8 man team.  Whilst David, Maurice and John did some tidying up of the site, the key focus was on digging foundations for the station platforms.  Alan had prepared a clever device for gauging the levels relative to the track, and the foundation trenches were dug by lunchtime, encouraged by a heavy rain shower.  After lunch the big generator was fired up and Jeff, Robin and Maurice got busy making concrete, while Alan tamped it to height - a successful afternoon.

Provisioning of Services.                         3rd April 2008

Despite a cool and wet end to March, work has progressed.  Ron installed the turntable's interlocking latches, and it has received a new coat of paint.  Also, a water line and power cable have been pulled through previously laid conduit to provide services for the steaming bays.  Plans are now being drawn up for the Station platforms, and for grass seeding some of the site.

The Turntable Lands.                             22rd March 2008

Following on from concreting the traverser bay, it was time to install the turntable.  Despite its size the installation was easier than expected just taking 3 people to put it in place.  After checking it worked as expected, and finding the true centre, the concrete base was drilled for fixing bolts.  The turntable has been finished to blend with the rest of the track, though is still awaiting the locking latches as designed and built by Ron.

The Big Mix.                                     3rd March 2008

As we enter the Society's 60th anniversary month, the last 2 weeks have seen much progress.  Ron & Dave have checked the whole length of the track base, straightening where required and tightening and fitting additional screws.  Between them Rob and Pete planted 5 more trees, and off site much of the rail has been prepared and drilled by Ted, Derek, Richard and Jack.

But the major event was the concreting of the traverser base, on another glorious day, making up for last year.
On 1st March, a team of 8 including Alan, Jeff, David, Robin, Graham, Roger, Jack and Rob worked together well, and the whole area was completed with a tamped finish in the day, with just 1/6th bag of aggregate and 1/2 bag of cement over.  This can now be left to dry out thorougly whilst the turntable is put in place.

Shuttering Done.                         16th February 2008

So far, 2008 has surprised us with kind weather, and again on this Saturday we were able to get on with important tasks.
A team of 4 spent several hours preparing ground at the top of the site, smoothing dips and bumps left by the bulldozer, while inside the club-house the turntable latches were being fitted.

But the main activity centred around a team assembling Alan's prepared timbers to form sturdy flat shuttering for the traverser bay.  Full length 70mm x 51mm timbers will be cast in, to be removed afterwards forming a recess for the traverser running rails.  The base has been filled with breeze blocks recovered from the old site.

Next the traverser.                       13th February 2008

With just a quick breather the next goal is a base for the traverser.  Roger has almost cleared the old track site and delivered about 2 tons of concrete blocks, and further old blocks were delivered by John T, to act as a rumble base for the concrete.

Meanwhile Alan has been preparing heavy shuttering for the base which is 9m x 2m with slots cast in for the rails, and tubes for electrics.  The area is already partly dug out and has now been pegged, and on Feb 16th a working party will finish digging, and erect the shuttering.

Dave has drawn up the paving plan while Ron is starting to modify the traverser recovered from the old site.

Concreting at last.                       26th January 2008

We could not have wished for a better day on January 26th - warm, dry and sunny (sorry Scotland), as a working party of 15 members tackled four different jobs.  The approach road was cleaned of mud, the small spoil heaps dug out from the turntable base were redistributed to fill in dips, and the big generator refurbished by Keith was returned to site and connected - and to much delight we now have working lights and power sockets in the clubhouse.

But the main event was the concreting of the turntable base, which had drained of water.  After some preparation the concreting took just over 4 hours of continous mixes with many broken up concrete blocks thrown in as a base.  This sturdy platform is the result of a great team effort.

The only casualty of the day was my car having a complete battery failure on site, so it was a quick exchange with the lawn mower battery to get home.

Turntable Excavations.                   12th January 2008

On this amazingly pleasant morning Alan, Jeff, John and Rob tackled digging out and shuttering the base for the turntable.  The very wet soil was becoming quite chewy by the time digging was finished, and as it then started to rain for the weekend, the next day it became a boating lake !

Deep in December.                   26th December 2007

Keeping up the pace, Dave and Ron were on site on a dry 22nd December, along with one of our neighbours and his bulldozer.  Within the morining they had remodelled the parking area; extended the length, pushed back the spoil heap, and built up the edges.

Also during the week John T. ferried more old track and other items away for recycling.   A fantastic job done, but with less than 3 months to the 60th anniversary we are hoping for more good weather in the new year.

Winter Working.                       15th December 2007

Despite turning slowly to winter, there is still plenty of activity.
A third Sunday morning effort allowed more sleepers to be recovered from Sandringham track site, a total of 42 for re-use.  Much of the old rail from Sandringham has been taken away for scrap, but some site tidying and a tip run is still required.

Keith is doing a grand job refurbishing the large generator off site, whilst Ron has rebuilt the steering gear on the mower.

On site, Dave has wired the club house with a fully protected ring-main and 4 fluorescent lights, whilst Ron has given the turntable a coat of primer paint.

Turntable assembled.                     17th November 2007

The previous weekend saw John T And Tony J remove the last of the soil mountain by hand, by all accounts enjoying the beneficial exercise !

Dave has repaired the electrics on the mower so hopefully it should now charge the battery.

On Saturday the curved turtable was assembled on its base for the first time indoors, and it not only looks stunning, but rotates very smoothly with just finger pressure; brilliant !

Season continues.                           4th November 2007

The good pace has continued with the kind autumn, and using a hired mini-digger and dump truck the steaming area and traverser bay have been excavated.  Working for 7 days Dave & Ron also moved the bulk of the excess soil from the upper parking area to raise the level elsewhere; followed by members levelling the dumped spoil manually.

A good turnout on Sunday 4th allowed us to retrieve 14 (full size) concrete sleepers from the old site, each is a 4 man lift.  So far, these have been used as road kerbs, and will be secured with long rods.  Keith has volunteered to refurbish the generator and this has been taken off site.

Turntable welded.                           17th October 2007

Ces completed welding of the steel turntable today, the impressive 4M structure now needs painting.   At the old track Graham and Roger have completed lifting of the rails; when various items have been moved to the new site we can terminate the old site lease.

Derek has started infilling the bottom of the lower cutting with gravel laid over sheeting, to act as a weed suppressant.  An old ride-on mower aquired by Rob has arrived on-site; although requiring a little attention, this should help keep the site presentable once seeded.

Boarding completed !                       12th October 2007

The extended summer has meant warm days at the track site.  Today - Ron, Dave and Derek finished erecting all the raised trackbed and steaming bay spur line, including fitting all of the intermediate spacer blocks, and setting cambers.  Assembly of all the timber work has been achieved in a little over two months, and has emptied the club house of the stacks of planks and blocks.

The turntable has been welded up by Ces, though there is some finishing off to do; quite a heavy fabrication.  The next job will be sorting out a solid foundation for it.  Elsewhere Rob has built up some embankments and planted the first of a series of trees, both to enhance the site and to ensure our activities are carbon neutral; this compliments the planting being done by Pete in the steep embankment in front of the Club-house.

Progress Maintained.                       29th September 2007

The kind September weather has allowed for Dave and Ron to continue assembly of the raised track bed past the summit of the track.  Half of the total length has been erected, and they hope continue while we still have good weather, and the ground is not to soft.  A successful Saturday working party tidied up some ground and the new car parking area, and sorting out a permanent base for our water collection tank.  This weekend will see another Saturday working party, and a team is due to be assemble and weld up the 4M long turntable.

Summer at Last.                       11th September 2007

The July Club meeting was held at the new track-site, and was the start of numerous regular working parties, as finally the weather settled down.  Within days, some raised track support was assembled, Dave & Ron's team working out the best way to do it, while a Friday evening group dug out floor of the top cutting and remodelled the walls of the lower cutting.  Meanwhile the cement mixer has arrived, and the pre-cut steel pieces to construct the turntable have been collected.

Preceeded by a full strimming of the site, the major event on the weekend of 8 & 9 September was the return of the digger, and a fair support of members (despite clashing with the Ascot 100th M.E. exhibition).  This tackled the remaining earth moving jobs including slight lengthening of the ditch and remodelling of some areas, resulting in the site being quite transformed.  All the remaining track support poles, and those for the steaming bays are in place, and being cut to length.  Access for cars has been improved, and an additional car parking area has been excavated; but the site will need a measure of hand raking to smooth out the dips inevitably left by the digger.  Fantastic progress !

Consolidation Inside.                       30th June 2007

Despite the enormous amounts of rain we've had, the dug out brook has worked well, and we have not suffered flooding acros the top of the site as previously.  We're still waiting for the digger to return, and a cement mixer to be delivered, so really only strimming and weedkilling has been done externally in the last few weeks.

However, much activity has taken place inside the club-house.  The bearing for the 4M turntable has been prepared, converted from a lorry axle hub; and a team have bolted the pre-drilled blocks on to the top hats - these are now ready to slide on top of the track poles.

Poles installed.                                 22nd April 2007

While on site, the mechanical digger formed a new cutting at the top of the site, which will help to keep the gradients reasonable.  It was then used to push in over half of the tubular track support poles, which have since been marked and sliced to the correct height.  During the month the tanalised treated blocks were sent for treatment, then collected from the saw mill and returned to the club house.

Major Work Achieved.                     5th April 2007

What a week, what progress !  With the core team of Dave, Ron and Derek, supported by other members, all the timber blocks for track support have been sawn up and drilled ready for treatment. In addition the digger arrived on site on Wednesday, and the skilled driver soon had the brook dug out to the extent allowed at this time, plus a further small cutting, and ground levelling.

Work Commences.                     31st March 2007

During the week thick timber beams and steel tubes for the track support were brought to site, and on Saturday afternoon at short notice, seven members arrived to start cutting up blocks for the track supports, using a power saw and portable generator set up in the club-house. On completion, these blocks will be sent away for pressure tanalising.

Preparation Work Commences.         24th February 2007

The construction methods have all been agreed, and a modified route requiring almost no further excavation work has been selected by the Committee.  All materials are being ordered and preparations are being made for a production line of various components in the club-house.  Cutting back of shrubs near the track path was carried out this week.  We have the official route for the site ditch to be excavated to drain the field, but it is just too wet to bring a digger on site at present.  It will all start soon.

Club Hut Secure.         11th November 2006

Tim's team has now fitted secure shutters over the windows as a security measure, better to be cautious than risk a break-in.  The hut is slowly accumulating benching to provide workshop facilities for the track construction.  Some soil testing has been carried out and pretty much the whole site is quite soft, having been frequently saturated, and will affect the way the track is supported.  Dave's team has started pegging out the track shape, transposing measurements from the design done in Turbo-Cad.

A Building Rises         16th October 2006

Monday 16th saw a number of members arrive early on a warm but overcast morning, to monitor the manufacturer's two-man team assemble our new hut.  Members also installed drainage to take away rain water accumulating behind the hut.  Despite a brief thunderstorm, work was complete by about four o'clock and the building was left watertight and locked.

Some windows may be re-positioned to ensure good ventilation and one member will be making shutters to protect the glazing from intruders.  This is the first real club-house the Society has had, and it will be fitted out with a kitchen area.  For now it will be needed to store construction materials.

A Solid Foundation.         10th October 2006

At last some tangible work has been undertaken on site.  The concrete slab base for the new Club building was poured on 30th September, followed by the wettest weekend in months !  It dried out o.k. and is ready for the building to be delivered and assembled.

Finally some Agreement.         21st September 2006

Following what seems like an age, and intense negotiation over the fine print of the site Lease we finally have agreement; and after chasing (threatening), we have planning consent for the Club building.  This has enabled us to place an order for the new building which will be essential for storing materials during the track build.  Hopefully the concrete base will be laid and the building assembled (by the Supplier) during the early part of October, if the weather doesn't collapse.  Then we can get down to pegging out the track.

More road-works.         17th July 2006

After two weeks of exceptionaly good (& hot) weather, Dave's team has continued cutting back the overgrown areas, removing boulders and fallen branches, now nearing completion.

The Society has dug deep and re-employed the Contractor, who came back on 15th July and rolled in 90 tonnes more harcore to finish off the roadway, ensuring site access is safe in all weathers.

The next job will be to decide on the club house and prepare a foundation, we really want this up before the summer ends; and to peg out the track route.

Movement At Last.         24th June 2006

After weeks of wrangling; finally the Council's contractor came back to site this week to form the lower roadway onto the field, and to move some of the heaped soil to allow more parking area. An area for the base of the club-house has also been cleared.  The Club has had to share the cost of this work, but one member has personally paid for around 40 tons of hardcore to form the road to the club-house area.

Dave, Albert and Derek wrestled with cutting back a lot of the scrub that has grown since the field has become unattended, and chain-sawed much dead-wood.  The owner of the adjacent field also kindly brought in his tractor mounted mower, and the area is looking very good.

Progress Update.         23rd April 2006

Spring now firmly with us, but still no sign of the brook being dredged.  Much work has been done by Dave Ashwell to plan for acceptable track gradients.  The Steering Group is due to make a presentation of the current thinking to the Club's April meeting.  The Society has been awarded a Grant which will probably be used to purchase a building, to provide a store, and later a club house.

Permission Granted.         22nd March 2006

Another site visit was made by Dave and Derek with the Council engineers.  Clearing of the top end of the brook should be done by the end of the month; this should allow much of the ground to dry out. Permission to start on site was given on March 15th.  However our construction will need to start at the top part of the site as there will be substantial engineering works to the culvert for a number of months.

Site Visit.         27th February 2006

The Track Committee assembled at the track site on Sunday 26th, very cold.  Dave and Chris' survey of site heights makes the gradients look acceptable.  Very wet underfoot after the previous week's rain, and we hope the brook will be dredged soon.  After discussion, some re-pegging of the track route has been marked, following concerns over potential flooding of deep cuttings.  Awaiting permission to start on site.

Drainage.             13th February 2006

The Contractor returned to the site, and installed additional drainage to the new access road, but since then we have had little rainfall.  In fact it has been so dry that the 100 or so shrubs planted by the Council on the slope adjacent to the access road are struggling. The planned clearance of the watercourses has still not started and we're unclear when it will start.

The track steering Committee has met and considered many aspects of the site; and the track construction method has been agreed.  The next stage will be a site visit to double check the gradients and exact track route.

Access Road.         20th December 2005

During the latter half of November 2005, Contractors created the new access road.  This is to allow Council vehicles to access the watercourses, and the culvert under the dual carriageway for maintenance.  During December the site was very waterlogged from heavy rain as indicated in the photo.

We are looking forward to working in this lovely setting, and foresee this as a fantastic amenity - worthy of the Society's energies.
Through this we can safeguard model engineering interests in our community for many years.