Modeling a Model Railroad - Benchwork, 2nd Try

I have messed around with the layout configuration and making little buildings long enough. Its time to get back to the benchwork. Since the issue the first time was precision I decided to give up the knife and go to the saw. At least this way the two primary dimensions will be precise and foamed PVC is soft enough that I can tape them together and run them all through the scroll saw as a single block. Be patient this is really photo heavy.

The final track plan and a copy to be used on the model.
This version has the viaduct on the right side and the underpass/creek bed on the left. I have made the runaround as long as I can within the confines of those two elements. There should be room for 2 40' freight cars. There might be room for 1 40' and 1 50' freight car but it definitely won't clear 2 50' freight cars. Most of the car spots will be along the rear siding. There are only a few car spots on the front siding; far left, far right and just to the left of the viaduct. These buildings will, mostly be shorter, 2-3 stories at most (at least that's my thinking right now).

The design and, using the hobby table saw, eight identical pieces.

I used painters tape to wrap them together and then copy the design on to the top piece. And yes I used an actual compass to draw the curve.

Here are the supports all cut out on the scroll saw. Next to that are the cross pieces. Unfortunately they are not exactly the same length. They are off enough to bug me and I don't want to repeat the mistake I made the first time. 

Since it is really important to make sure the cross members are identical I laid them out on another piece of PVC and included the positions where I will need to cut notches.

Now all the pieces are cut and ready to assemble.

I started out just trying to figure out the best way to approach getting it all together.

All the cross members dry fitted into place at this place using just the two center supports.

I chose to start from the bottom with the center and back cross pieces. I worked from the two center supports outwards. Its still a bit twitchy at this stage but you can tell that it will be a pretty rigid structure,

Back cross piece in place.

Top cross piece in place and its pretty solid at this point.

A look at the how the two modules will look when fastened together.

Here the top plate and the top front fascia have been added.

This shows the bottom wear plates and the bottom fascia.

And a completed module just waiting for some scenery to be added.

I had to use clamps but here are the completed modules in position.

How it might look with the track and buildings in place.

And a bit of an overhead view.

The next phase will be to figure out how to fasten the two modules together, cut the track plan into two sections and make the benchwork cut out for the underpass/river portion on the left.