by Scott Meyer/photos by the author
I built my first portable layout partly from necessity. I was the only N scaler in the club I’d joined and had no place to run my trains. I also wanted to participate in the shows where the club displayed its portable HO layout. I was given a “standard” 6×2’ module to use for my stand-alone project. It was framed with 1×4” lumber with a plywood top and four 2×2” legs. I built a nice little N scale layout using plaster scenery material. It was portable but needed two people to transport and set up.
Then a club member asked me to build him a Z scale portable. People at the shows asked him if N was the smallest scale and he wanted to show them it wasn’t. He had framed out a 4×2’ wood rectangle with 1×4” lumber to start with. By now I was acquainted with foam insulation as a building material, and using it ended up with a much lighter result.
It was time to update my own portable. Using foam and 1/4” plywood as fascia, it was 5’ x 28” and weighed 28 lbs. Having recently changed scales to HO, I wanted to build myself a new portable. I swore I could do better, lighter and more portable, but knew it would be an experiment.
![Lightweight Portable Layout](https://rrmodelcraftsman.com/wp-content/uploads/2024/03/rmc-lightweight-portable-layout-02.jpg)
My storage space was maximum 72” by 18”, it had to fit under my 18”-wide shelf layout. I found a track plan by Rob Chant on the Facebook group “Journal of Model Railroad Design” that fit my needs perfectly. Lengthened by just six inches, the footprint was 66×18”. Your layout size may differ, but I would be wary about exceeding 72×40” as you may find the materials may not hold up to constant moving and storage.
Construction
I planned to use two 1”-thick sheets of foam glued together, with .06” styrene as the 4” fascia and 12” backdrop. I had used this material for a free-standing backdrop across a 6’ window with good results. Four wooden joists would span between the front fascia and the backdrop. Glue and a few screws would tie these elements together to form a sturdy, rigid and light platform for my project.
Interstate Plastics is a good source for styrene. They sell 4’x8’ sheets and cut to order. My project required five 4”-wide and one 12”-wide 6-foot strips. Cutting the 4’x8’ sheet into shorter lengths reduces shipping cost considerably! Have the rest of the styrene cut into shapes you can use for other projects.
![Lightweight Portable Layout](https://rrmodelcraftsman.com/wp-content/uploads/2024/03/rmc-lightweight-portable-layout-03.jpg)
Please note that the only adhesive used is Liquid Nails For Projects. An inexpensive latex-based construction adhesive, it bonds well, sets quickly, and will not attack the foam like other solvent-based adhesives.
I cut out the space where my coal trestle fit, also cutting slots to separate the ramps leading to it. I use layered foam on all my layouts now. The lower sheet provides a flat, level surface for waterways and other depressed features. Cut the top layer to the contours you need and don’t get glue on the base in those areas. I used a hot wire tool.
Next, glue and clamp the sheets together. Now fashion the wood crosspieces using 1×2” lumber cut into four 18”-long joists. They are topped with a 2”-wide strip of 1/4” plywood the same length. Glue them together forming two L-shaped girders and two T-shaped. Don’t forget to drill holes for your wiring! The L-girders go flush with the ends of the foam with the plywood glued to the underside of the layout. The T-girders are glued 22” in from each end. Place the joist side down on a flat level surface. This way you will be able to see and adjust the joists to be perpendicular to the foam. Place weights on the top while they set. I used a 5 ft. folding table to weigh mine evenly.
![Lightweight Portable Layout](https://rrmodelcraftsman.com/wp-content/uploads/2024/03/rmc-lightweight-portable-layout-01.jpg)
Now cut the styrene fascia. One 4”-wide strip 66” long for the front, two 18” long for the sides and cut the 12”-wide strip 66” long for the backdrop. The rest of your 4” strips are for the staging module.