Benchwork

The layout bases will be of a lightweight modular style, employing the design and construction techniques developed and practiced by The League Of Non-Aligned Modelers over a period of some 25 years. This method differs considerably from more traditional module designs in the generous use of thin, 1/4" or 5mm Luan Ply, which is more commonly known in the construction arena as door skin plywood. Known as 'waffle modules' by the League, when completed, the modules bear a striking resemblance to a one-piece cast freight car underframe design of the 1890-1930 period.

The skins are cut to a 30" width for most modules, and are 'waffled', or lightened, by the careful removal of about 50 percent of its bulk. A gridwork pattern remains in the skins, to which rails of 3/4" Birch plywood, cut to the length of the module minus 1 1/2", and 4" in height, are glued along each edge, and along a parallel line 9" in from each edge. End pieces 4" high and 30" long are also cut from the 3/4" Birch ply, and are glued both to the skins and to the rails. These end pieces have a hole-and-peg alignment system which guarantees that each module fits into the next module precisely.

Cross members of 3/4" Birch plywood, cut to a width of 3/4" [or 1"] and a length to fit between the rails, are glued to both the top and bottom skins and to the rails on a 12" spacing. No attempt is made to notch the rails. These runners are only meant to keep the Luan from sinking between the rails. The strength of the module comes from a combination of the rails and the skins forming a single structure when the glue has dried.

The beauty of this design is that one single 8' module can be lifted by one person using only one hand. The weight of a completed League module is less than 30 pounds. A more traditional module of the same size can easily pass one hundred pounds.