Planning Calico: A Portable On18 Layout

The Calico Gold Company will be a 24" x 60" portable layout in On18 scale. Based loosely upon the Calico Mine Train at Knott's Berry Farm, the layout will also act as a feeder line connecting to the TMMC. Minimum radius on this plan is 10" and the ruling grade is 5%.

For a long time, I've been mulling over ideas for a small, portable layout or module that could be taken on the road to shows and modeling exhibitions as a representative sample of what Thunder Mesa is all about. I've also been toying with the idea of doing something in On18 that could act as a feeder line for the main railroad. And regular readers of this blog will know that I'm a huge fan of the Calico Mine Train at Knott's Berry Farm in California, having pretty much spent my youth there when I wasn't just down the road at Disneyland. Well, all of those ingredients have finally come together in a new 2' x 5' layout project that will showcase the style of Thunder Mesa while paying tribute to some of its Knott's/Calico inspirations.

A 1960's vintage postcard of the Calico Mine Train at Knott's. Just as the TMMC attempts to imagine a prototype for Big Thunder and Natures' Wonderland, the new Calico mini-layout will appear as something that could have, if it existed, inspired the attraction. The idea is for a model that shares visual cues with the Knott's attraction while not trying to be a slavish copy.

What the Heck is On18?

On18 is a funny scale/gauge combination that is intriguing to a dyed-in-the-wool rubber gauger like myself. It uses N gauge track and mechanisms as a starting point for 1/4" scale models in one of the slimmest of slim gauges. The 9mm gauge N scale track works out very close to 18" in 1:48, happily, a rather common track gauge for industrial and mining railways. The resulting models can have a lilliputian charm and character that really appeals to my sense of whimsy.

Concept illustration for a freelanced On18 locomotive inspired by the Knott's Calico Mine Train. This tiny drivered 0-6-0 will measure just 3" long in O scale and be powered by an N scale Atlas 2-6-0 mechanism. As a point of comparison, a diminutive Bachmann 0-4-0 Porter in On30 is a good inch (four scale feet) longer.

I've gone back and forth on the idea of an On18 feeder line several times; adding it and then removing it from subsequent track plans. Experience has taught me that if an idea keeps coming back around again and again, it's probably solid and eventually I'll have to do something with it. Well, the time has come and my long delayed plans for Calico will at last be moving forward with tiny trains on some very slim rails.

Refining the Concept

Designing the simple over-and-under figure eight track plan was the easy part. Figuring out where and how it will fit into the larger scheme of things on Thunder Mesa was the real challenge. Not only do I want the layout to be light and portable, I also want it to "plug-in" to the main layout as seamlessly as possible when not out on the road. It took some creative engineering and more than a few major tweaks to the TMMC plan to get all 10 lbs of both railroads to fit into the 5 lb sack of my art studio. I'll explain the changes to the TMMC plan in another post in the near future.

I still draw my plans the old fashioned way, with pencil and paper. I went through a lot of both figuring out where to place the Calico module within the larger scheme of the layout. There will be more on the updated overall plans for the TMMC in a future post.

Parts from Other Scales

Working in an oddball, niche scale like this means that just about everything needs to be scratch-built, kit-bashed, adapted or modified from materials, models or details in other scales. That's a big part of the fun as far as I'm concerned. Figuring out which bits and pieces from the smaller scales that can be useful is an interesting challenge. For example, I'll be using Peco HOn30 track and turnouts since the big, chunky ties and spike detail will look right at home in On18. Many carefully selected HO scale items can come in handy, especially things like locomotive detail parts and freight car frames. 18" gauge trains are small, so the roughly half-sized HO parts should work fairly well. Of course, N scale wheals and mechanisms will be used to model rolling stock. The trick is to find donor mechanisms that run reliably and that can be modified into something somewhat believable. I've already begun tinkering with a smooth running Atlas N scale 2-6-0 mechanism, removing the pony truck and mocking up ideas for the frame and cab. This may form the basis for Calico's first locomotive as illustrated above.

The 1:48 scale mechanics aren't quite sure where to start, but some HOn30 track, N scale mechanisms, HO parts and O scale details all get thrown into the mix when modeling On18.

Scenery and Structures

Naturally, figures, scenery and structures will be built at 1:48 scale, though since most buildings will be "smaller than life" caricatures, they will need to be scratch-built as well. Some structures, like the Calico Mine Co. warehouse below, will be modeled directly after the originals at Knott's, while others will be designed to fit the available space.

Color elevation plan of the Calico Mine Co., drawn from photos of the loading area at Knott's Berry Farm.

The scenic highlight of the layout will be Calico Mountain with its distinctive rock spire and waterfalls. No attempt will be made to replicate the interior scenes from the attraction but the dramatic high trestles and mine tunnels will be there, along with a truncated version of Calico Ghost Town - now very much alive with lighting, animation and sound effects.

Another vintage postcard from Knott's showing the spectacular sandstone spires of Calico Mountain along with the loading platform for the Mine Train.

Lightweight Construction

Since the layout will be portable, I'll be building it as tough and light as possible, using mostly polystyrene foam and very little wood. I developed a method for "cookie-cutter" foam benchwork for an N scale layout built some years ago and I'll be reprising that technique again here. The technique uses polystyrene foam sheet cut and fit very much like dimensional lumber for benchwork that is strong, sturdy and mostly air. Sub-roadbed is then cut from foam, cookie-cutter style, and glued into place with foam risers for elevation. I'll go much more deeply into detail on this lightweight construction method in a future post.

The Calico Gold Company will be built almost entirely from polystyrene and urethane foams. The integrated backdrop will be stretched canvas. The goal is a finished layout that can be lifted off of the larger Thunder Mesa pike and then travel to shows. A simple, folding stand will be constructed for the layout to sit on when it is away from home.

For the backdrop I'm hoping to use stretched canvas on a light wooden frame, very similar to the way theatrical scenery flats are made. The backdrop will be integral to the layout, both as an extension of the scenery and as additional structural support. If all goes well, it should be much lighter and more flexible than Masonite and will also serve as proof-of-concept for the entire backdrop system on the larger Thunder Mesa layout.

Much More to Come

With a plan I'm finally happy with it's time to get modeling and move forward. I'm not sure how long building Calico will take me, but as it's integral to the overall scheme of Thunder Mesa, it will be worth the time and effort to get it well started. No doubt there will be side projects and distractions along the way, and there is still so much to be done on Thunder Mesa proper that I should be very busy well into the future. Thanks for checking in, amigos. January has already raced by with a load of fun projects and the rest of 2015 looks like it will be a humdinger. Adios for now!

Engine Roster for the Thunder Mesa Mining Co.

A reader recently asked a question on Facebook about the locomotive names and numbering on Thunder Mesa and it made me realize that I have never really published a complete engine roster for the railroad. The roster has changed and evolved a bit over time and will no doubt continue to do so as new equipment comes available and the railroad continues to grow. For the most part, I name locomotives after the Disney animators or Imagineers that I most admire, or other pioneers in the world of theme park railroads such as Bud Hurlbut. Currently, there are five locomotives running on the layout with at least two more planned or under construction.

No. 1

No. 1  - Marc F. Davis

Wheel arrangement: 0-4-0
Builder: Thunder Mesa Mining Co.
Entered service: 1878
Notes: This unique vertical boiler, single piston steamer was built from the recovered wreckage of a steam launch and the 2-4-0 El Dorado. Placed into service in 1878 to help complete construction of the railroad. Named for the proprietor of the Western River Expedition Company.

Modeling notes: Scratch-built from spare parts on a Bachmann HO cable car power truck. Analog DC power. No sound. Click here for more on the Marc F. Davis.

No. 2

No. 2  - Claude Coats

Wheel arrangement: 2-4-0
Builder: H.K. Porter, Inc.
Entered service: 1879
Notes: Light duty mining locomotive named for the discoverer of Rainbow Caverns.

Modeling notes: Planned but not yet built. Inspired by Disneyland's Nature's Wonderland locomotives, the #2 will more than likely be built using a Bachmann 0-4-0 Porter with DCC and sound. Claude Coats was the brilliant Disney Imagineer who developed the lighting and water effects for Rainbow Caverns.

No. 3

No. 3  - Sam McKim

Wheel arrangement: 4-4-0
Builder: Freelanced
Entered service: 1879
Notes: General duty locomotive named for the first surveyor and cartographer of Thunder Mesa Country.

Modeling notes: Under construction. Inspired by the Santa Fe & Disneyland Railroad, #3 is a diminutive 4-4-0 that uses a Bachmann HO Richmond 4-4-0 as a starting point. Sam McKim was a first generation Imagineer and Disney artist who created the early souvenir maps of Disneyland among many other things.

No. 4

No. 4  - Earl Vilmer

Wheel arrangement: 4-4-0
Builder: Freelanced
Entered service: 1880
Notes: General duty locomotive named for the first general manager of the TMMC.

Modeling notes: Bachmann On30 inside frame 4-4-0. Inspired by the Santa Fe & Disneyland Railroad. DCC installed, sound to be added. Earl Vilmer supervised the construction and operation of both the Disneyland and Walt Disney World Railroads.

No. 5

No. 5  - Frank Thomas

Wheel arrangement: 0-4-2
Builder: H.K. Porter, Inc.
Entered service: 1881
Notes: General duty mining locomotive.

Modeling notes: Bachmann On30 0-4-2. Needs paint and decals. Inspired by Big Thunder Mountain Railroad. DCC and Tsunami sound on board. Frank Thomas was a legendary Disney animator, one of the Nine Old Men and best friends with Ollie Johnston. 

No. 6

No. 6  - Ollie Johnston

Wheel arrangement: 0-4-2
Builder: H.K. Porter, Inc.
Entered service: 1881
Notes: General duty mining locomotive.

Modeling notes: Bachmann On30 0-4-2. Inspired by Big Thunder Mountain Railroad. DCC installed.  Ollie Johnston was a legendary Disney animator, train enthusiast, one of the Nine Old Men and best friends with Frank Thomas.

No. 7

No. 7  - Bud Hurlbut

Wheel arrangement: 0-4-0
Builder: H.K. Porter, Inc.
Entered service: 1883
Notes: General duty mining locomotive named for the discoverer of the Calico Mine.

Modeling notes: Bachmann On30 0-4-0. Needs paint and decals. Inspired by Knott's Calico Mine Train. DCC and Tsunami sound on board.  Bud Hurlbut was a pioneering theme park designer best remembered for creating the Timber Mountain Log Ride and Calico Mine Train attractions at Knott's Berry Farm.

That's where the roster stands as of this writing. Will there be more? Probably. Even though the TMMC already has more locomotives than a mining railroad of its size would likely ever need, this modeler simply can't resist the temptation of a shiny new engine every now and again. Besides, there's not a single geared locomotive yet and I've always been a fan of geared steam! Stay tuned. Adios for now!

Aerial Views and Expansion Progress - May 2, 2014

Changing Plans

The nice thing about plans on paper is that they are easy to change.

Last Friday's post on Knott's Calico Mine Train inspired me to go back and take another look at the expansion plans I have for the TMMC, and especially at the corner Calico section. To be honest, I was never fully satisfied with the plans for that corner and taking a fresh look at Calico had me wanting to incorporate more of the look and feel of the Knott's original in my layout. To that end, I spent a couple of days figuring things out and now have a revised plan for the Thunder Mesa expansion.

The upper lefthand corner has been completely reworked with a much more spectacular presentation of Calico Mountain, its waterfalls and dramatic trestle. Now trains will pass in and out of the mountain on multiple levels, much like the Knott's attraction, and a reverse loop will send them back toward Thunder Mesa. Gone are the engine shed and turntable once planned for this corner, but the long spur up to Big Thunder Mine still remains.

On the left is the old version of Calico with its engine shed and turntable. A functional scene but not one that really captures what I'm going for. On the right is the updated plan for Calico, a scene with much more bang for the buck and the added interest of a reverse loop. I was sorry to loose the engine house but it's easy to pretend those facilities are just over on the other side of the mountain somewhere.

I've had to give up a wee bit of aisle space with this new scheme but the trade off in scenic potential should be more than worth it. A 3% grade still brings trains up to Calico, and the natural bridge, balancing rocks, deep canyon and Indian pueblo are largely unchanged. I did change the size of the Calico section from 3'x4' to 6'x4', and this in turn now makes the canyon section 5'x3' instead of 8'x3'. It just seemed to make more sense to have two medium sized sections.

Construction has officially begun on the Calico section, with the benchwork already completed and the 1/2" plywood sub-roadbed well underway. And that bring us to this month's aerial views.

Last month: April 4, 2014.

Today: May 2, 2014. 

Here you can see the new 6' length of the Calico section and the beginning of the 3% grade.  A cutout in the benchwork marks the future location of Natural Bridge. Calico Mountain will occupy most of the far corner and should make a nice balance with Baxter's Butte.

In the next section of benchwork, the scenery will plunge dramatically as the trains cross Bright Angel Canyon on their way up to Calico. With any luck I'll be able to get that built later this month and can start looking forward to running trains through the new sections. Stay tuned! Thanks for checking in, folks. Adios for now!

Thunder Mesa Inspirations #3: Knott's Calico Mine Train

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Jumping into Rainbow Caverns

"Now we're going deep into the earth to view the dazzlin' Rainbow Caverns! You'll see giant stalagmites, stalactites 'n colorful falls on every side..." 

- Recorded narration from Disneyland's Mine Train Thru Nature's Wonderland.

Let's Go Spelunking!

After a couple months away from working on the TMMC I figured it was high time to jump back in with both feet and get started on a major project again. Some version of Rainbow Caverns has been integral to the idea of Thunder Mesa ever since I first happened on the idea of freelancing a Disney-esque railroad. Until recently the Caverns have been an empty foam box that trains travel through, but now I aim to remedy that with scenery, animation, sound and lighting effects; creating a colorful underground world seldom seen on a model railroad. I won't try to recreate the Disneyland version scene by scene. Instead I'm going for something more like an homage that captures the feel of the original, along with a little of Knott's Calico Mine Train salted in for good measure.

Geyser Grotto in Rainbow Caverns on the Mine Train Thru Nature's Wonderland, Disneyland USA. © Disney

Cavern scene on the Calico Mine Train, Knott's Berry Farm, USA.

Planning the Caverns 

Rainbow Caverns will be constructed as two separate scenes, each one executed like a small diorama. The first scene will be on the original section of layout almost directly beneath the town of Thunder Mesa. A second, larger scene will be built beneath the Calico Section once track has been laid through that part of the expansion. Since the track and most of the infrastructure is already in place for the first scene, I'll be starting there.

The area for Scene 1 currently has the exterior scenery roughed in with pink foam and the interior painted flat black. The scene will be viewed through cave like openings in the cliff wall and a large hunk of this wall can be removed for access.

Scene 1 of Rainbow Caverns will be viewed through these cave openings in the cliff face.

Here a removable section of scenery has been placed to one side to enable work on the interior of the caverns.

A Backdrop for the Diorama

Scene 1 will be a classic "wet cave" with rushing waterfalls and a large chamber filled with stalagmites and stalactites. In addition to lighting and sound effects, one of the most important elements for making this shadow-box like diorama work will be a convincing backdrop. Since I'll literally be working "inside the box" in rather close quarters, it just makes sense to paint and install this internal backdrop before any more work is done.

I created my Rainbow Caverns backdrop on a 5" x 15" piece of  Strathmore illustration board. Working from the darkest shades to the lightest, I painted the cavern scene with artist's acrylics, using photos from Disneyland, Knott's and real world caverns for reference.

The completed Rainbow Caverns backdrop ready to be installed on its shadow-box diorama. The colors are intentionally over the top, nearly florescent, in order to show up well in the dim cave. They don't call 'em Rainbow Caverns for nothing!

And here is the scene with the backdrop in place. It's a little difficult to photograph without any lighting installed yet so I composited a couple of pictures in Photoshop to illustrate how it looks in person. The next step will be constructing some 3-D cavern scenery to blend with the backdrop. Just in front of the locomotive in this shot will be a ceiling to floor waterfall, animated by fiber optics lights.

Several LEDs will be used to light the interior of the Caverns, including some ultraviolet lights. A hidden speaker will provide the sounds of running and splashing water.

On Down the Line

With the all important backdrop painted I can proceed with building the rest of the scene. Next will come some unusual subterranean rock formations carved from polystyrene foam and painted to blend with the backdrop. Then I'll try and tackle an animated waterfall with twinkling fiber optics. Should be fun!

Thanks for checking in. Adios for now!

A Grand Plan for the Thunder Mesa Mining Co.

At long last, here is the "Grand Plan" for the expanding TMMC. This should give a good idea as to where the layout is headed, and help to make sense of the construction updates I'll be posting. I've been thinking "out loud" about this expansion here on the blog for awhile. Some things I thought might be included, or had planned to include in the past have ended up on the cutting room floor, while other possibilities I hadn't considered found their way into the plan as it was being drawn.

Click the image for a much larger version.  Grid spacing is 12".  Overall size is 11'x8'.

The layout will operate as a simple point to point design, with ore trains coming down from the mines at Calico, headed for the mill and an interchange with the Santa Fe, Denver and Carolwood at Thunder Mesa. A daily mixed train will head up-grade in the opposite direction, carrying freight, supplies, passengers and mail from Thunder Mesa to the far-flung mining camps. An excursion train or two will also be on the schedule, taking wide-eyed tourists for a ride through "Nature's Wonderland." Continuous loop running will still be possible using the hidden cut-off track below Thunder Mesa.

It's funny, but for the longest time I had thought of Thunder Mesa as being way out in the boonies, near the end of the line and far, far from the SFD & C interchange (which was originally to be located in another town called Grizzly Flats. That town still exists in the make-believe world of Thunder Mesa, but it's aways north now and off the layout). While creating this plan I discovered it made a lot more sense to have the interchange be in Thunder Mesa itself, with the ore trains serving the "mines above" much like the real-world Gilpin Tram once did in Colorado. Once this decision was reached, the entire plan and operating scenario fell into place.

Another idea that got rejected was the On18 tram from Calico. As fascinating and fun as I think it might have been to run those tiny trains, there just wasn't enough room for it and the On30 mainline I wanted to build. So now, the On30 line climbs a steady 3% grade up to Calico and on to what had once been planned as an On18 right of way. (I still might build a separate On18 module in the future. Time will tell!)

The layout is being constructed in three separable sections as illustrated below.

The Thunder Mesa section is roughly 4'x8' and is more than half complete at this point.

The 3'x4' Calico section is the future home of an engine facility with a 36' turntable. Down below, open caves will provide views into more of Rainbow Caverns.

The Canyon section is 8' long and drops the base of the layout about 14" to provide adequate depth for the dramatic vertical scenery planned here.

The good news is that nearly all of the scenic elements I wanted to include have made it into this final version of the plan. Heading up-grade from Rainbow Caverns, trains cross Natural Bridge, a breathtaking and precarious sandstone span. That leads into Balancing Rock Canyon, a land of strange hoodoos that seem to teeter and sway as the trains rumble past. Just beyond, Indian Pueblos sit atop a high mesa overlooking the grandeur of Bright Angel Canyon. A pair of spidery bridges span the canyon itself, the longest and highest being a scale 120' and some 94 scale feet above the churning rapids of the Rio Del Barranco far below (On the backdrop, I'll do my best to replicate the views of Disneyland's Grand Canyon Diorama). Then it's on to the Calico mining districts where the line makes a graceful curve below the overhanging alcove of Calico Mt. before winding to its end near Big Thunder Mine.

For those who may be interested, I draw my plans out by hand in pencil on 1/8"x 1/8" blue-line grid paper at a scale of 1/8" = 1". The completed drawing is then scanned to a digital file and colors and graphics are added in Adobe Photoshop.

And there you have it, a Grand Plan for Thunder Mesa that should keep me busy working on the railroad for quite some time to come. Thanks for checking in. Adios for now!