Scratch Building For Everyone
Topic: Structures

Finding all of the buildings need to fill the MK&P without repeating the same kits over and over is not easy. Kit bashing is my favorite answer to this problem. While bashing a kit, however, I may discover there is an element needed for the project which cannot be fabricated from the parts available in the kits or from my scrapbox. Sometimes all I need is a small, simple part. At other times, however, when building a large industrial complex I may need an entire structure because nothing similar exists in kit form.
I think many model railroaders, myself included, are intimidated by the thought of scratch building. It brings to mind articles in modeling magazines by skilled craftsmen who have devoted months or more in research and the building of complicated and highly detailed models of a specific prototype. And there are those awesome models encountered in the contest room at an NMRA or some other convention. I shuddered as I browsed through a recent publication and found an article documenting a prize-winning stamp mill with a fully detailed interior and machinery which actually operated! Amazing - but intimidating
There is nothing like necessity to push you into doing what you're reluctant to do. I've found building something from scratch doesn't always have to be one of these daunting tasks. The MK&P is set in the contemporary era. Many modern industrial buildings aren't much more than simple steel boxes with few windows or doors and some added do-dads. I also have the advantage of modeling in N scale. In this smaller scale I find you can get by with fewer details and still have an acceptable model. So be not afraid to try your hand at scrachbuilding.
When I struck upon the idea of adding a cement factory to the layout, I had no idea what I was getting myself into. What inspired me was the thought that the Walthers HO Medusa Cement Company kit could be converted for use as the storage silos of an N scale factory. I soon became aware those silos were not the only thing required to have a rail customer which manufactured cement. To the right is an ariel photo of the cement plant which is still under construction. Although not yet finished all but one of the needed structures (the clinker storage) are now in place. They are a combination of kit bashing and scratch building.
After acquiring the HO kit I set about determining how it might be converted to N scale. The most obvious thing was the shed for unloading HO hopper cars which shouted "HO scale". It would have to go. Happily, the truck portals in the silos were just the right size for N scale hopper cars. The overhead steel doors were molded closed, however. A bit of work with a saw and knife opened the doors.
So I had my silos for storing cement and loading hopper cars for shipment. Now what was I going to do for the rest of the plant? Time for some research which the wise modeler might have done first. I began with a search of the web. On the Portland Cement Association website http://www.cement.org/manufacture/ I found a virtual plant tour and other helpful material. Next, I went to the on-line magazine index at Trains.com. That turned up articles in the Rail Model Journal and Craftsman magazines. With this information in hand, I could proceed with the design and building of the other elements needed for a cement factory.

The first order of business was to find a replacement to the shed for unloading HO hopper cars. The RMJ article of May, 1995, included a drawing of a baghouse/warehouse. With the drawing as a starting point, I created my own building which would receive empty boxcars for shipping bagged cement.
Not being an experienced and talented scratch buildder, I kept it simple with only enough details to communicate the purpose of the building. As you can see in the photo the building is basically three boxes, two on either side of a taller cental one. The office portion is not visible but is nothing more than a small narrow box with a lean-to roof at the far end of the building. A tower (painted brown) sits on the roof.
I may add more details later or even construct a replacement. But following the "good enough" principle this will do for now. This is indicative of all my current scratch building. It is but one of several structures in a complex. To my way of thinking, most layout visitors are going to be looking at the overall scene. With several things to look at the details of each individual structure won't be getting a lot of their attention. I have a lot of real estate to cover and not unlimited time in which to do it. I think this is an approach which can be useful for many layout builders. I believe a number of us become impatient and ultimately discouraged by slow progress. I am not advocating sloppy work, but there may be value in maintaining momentum at the cost of leaving some details for later. The silos and baghouse were only two of several structures which I needed to build.

Standing just to the left of the silos is another scratch-built structure, the milling building. Again, as with most buildings, it is nothing more than a series of boxes combined into a single structure. The flat roofs make the box character even more apparent.
In this view of the west end of the cement factory the two white buildings at either side are the latest scratch building projects. The one on the left is the materials storage building and the one on the right holds the furnace for the kiln. Not sure at first what to do for these buildings I received inspiration from the Walthers HO cement factory kit. This kit is not yet available in N scale, but the buildings are uncomplicated which is one of my prime criteria for scratch building.
To design these buildings I did some paper cut-outs of the end profile of each building. I took these out to the layout to compare them to the other structures. After three or four tries with various sizes and proportions, I arrived at what seemed suitable. I also had to consider the dimensions of the space available and the need to place a drive motor for the kiln inside the furnace building.


You can see the two boxes which make up the furnace building. I selected styrene sheeting with a pattern to match the siding of the pre-heating tower which is located at the opposite end of the kiln. The pre-heating tower is another modified HO kit.

The materials building is where the limestone from the adjoining quarry will be stored along with other ingredients of cement which will be arriving by railcar. These heavy materials are held in concrete bins which form the greater portion of this building. I built it with smooth styrene sheets. On top of this base is a sheet metal collar and roof. Alongside I built a shed of sheet metal to receive hopper cars for unloading incoming materials. The quarry will located in front of the factory and therefore will be off the layout. To imply it's presence I'll need to build a conveyor to the materials building.
I hope you can see from this example it is possible for everyone by choosing uncomplicated structures to scratch build models which will work for your layouts. Further detailing can be added later as your skills grow or more time becomes available.
Posted by The Station Master
at 10:10 PM CDT
Updated: Monday, 31 October 2005 8:14 PM CST