Double Helix construction pictures
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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About a year ago I decided I would like to build a double helix. It had to be modular in form so it could be taken to shows. Each helix will be in four sections. The different levels had to be adjustable so I decided to use 7/16" all thread with nuts and washers.
The up side of the helix I'll use 0-60 Fast Track and the down side will be 0-54 tube track.
To start the layout proceedure I used this simple method of construction paper and a compass.
Then laid some track out on 1/2" plywood, looks like I can get 9 sections.
Just used a jigsaw to cut out the sections.
SPINNING THE NUTS;
Seeing how each helix would have more than 125 nuts to spin I came up with this method to help.
I started off with a 1 1/2" drum sander and added a couple large washers to help the belt track better.
I then got a 1/2" drive long socket. This is the reason I selected 7/16" rod so it would fit thru the socket. I also got a vacuum cleaner belt, the largest one I could find.
This is what the operation looks like. Sometimes the belt would come off the drum if I didn't hold the drill at the right angle
Time for a coat of primer.
Here it's assembled on the kitchen floor, bet it won't stay there long 
This is the 0-54 down side.
At this point this project has grown larger than my house will hold so I joined the local HO club who has their layout in a large warehouse about 20 miles from home. However they gave me about 3000 sq.ft.to use so it's worth it.
I've painted the larger hilix brown.
I built this bridge a couple years ago for another project so will try using it to span the two at the top.
At this point in the construction I was still thinking that this would be displayed on the floor. So I came up with this idea for bridge supports. Just cut them out of 2"x6" pine.
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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BUILDING THE TABLES
I had saved some shelving from our kitchen remodel so will use them for the table tops.
Here I've decided to make the table sections kind of interlocking to be more stable when bolted together.
This shot is before I trimed the boards.
I used 1"x4"s as facing.
This is one table put together with one section on helix
This is showing both tables with the top bridge resting on the tables.
This is showing the bottom cable bridge resting on a temporary table. It will be raised about 6 inches.
Table facia painted black.
At this point I've realized that the tables will have to be moved further apart and I'll have to do some modifying on the top black bridge. Once the distance is determined between the tables I'll make a water feature of some nature. It will be one section to lock the two tables together.
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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MAKING "T" NUTS
Now I have to find a way to secure the allthreads to the table. 7/16" T nuts are not available through any sources that I could find. Therefore I'll make my own.
I started off with flat square nuts and large 1/2" opening fender washers.
I drilled 3 holes in each washer to accept a #4 screw and used Grollia Super Glue to attach the nuts to the washers.
I made this simple little Jig to hold the washers while drilling the holes with the drillpress.
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JohnBoy
Joined: May 14, 2008
Topics: 110 Replies: 517
Topics: 110
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Fabulous project, and it's going to be a hoot watching trains run around this setup. Very much looking forward to updates as you progress through this. Also, if you can shoot some video of trains running on it, let me know if you need any help getting that onto YouTube or something, and we can embed it into a post here.
Really cool idea!
John
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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VIDEO at RoundHouse South in Port Orange Fla.
This was some of my inspiration to build a helix
Double Helix Video
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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This is the begining of my water feature, I'll be adding darker colors to give the water depth. I'll also paint the bridge bases to look like concrete. I've also added blue to the back wall.
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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The Super Glue was not strong enough to hold the T nuts together. A train buddy of mine who is a pretty good welder offered to weld them together for me. Thanks Wayne.
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JohnBoy
Joined: May 14, 2008
Topics: 110 Replies: 517
Topics: 110
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Sweet! Custom welding - now that's dedication to the hobby and craft!
John
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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Today I sprayed them with a flat black primer and turned them onto the allthreads. Once the table tops are painted a dark color they'll blend in.
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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The above pictures are for a static display only. Still a long way to go before powering up.
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t8afao
Joined: Jul 23, 2010
Topics: 39 Replies: 64
Topics: 39
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Looks like your RMT Bang did well pulling the cars up the helix. Nice work and photos on how you did this project.
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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Getting closer to seeing this in operation;
These are the columns I made to support the top bridge. Cut from 2 x 6's, groved with a hand saw and spray painted with the Fleck stone paint. The bases are cut from 2"x2"s.
The bases for the Gator Bridge were cut from 2"x2"s also.
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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The "Gator Bridge" as I call it is out for modifications so I'm building this temporary bridge to fill the gap.
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JohnBoy
Joined: May 14, 2008
Topics: 110 Replies: 517
Topics: 110
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Here's an updated video I was asked to insert:
Awesome!
John
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TRAINS4U2C2
Joined: Oct 4, 2009
Topics: 43 Replies: 71
Topics: 43
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I have added a black background cloth inside the helix, using weedblocker material. It's light and easy to work with, also inexpensive.
This picture is showing the vertical supports covered. ( sorry for the unclear picture ) I used 1 inch PVC pipe cut to length, then cut a small section off the back lengthwise so it would fit around the allthread. Then sprayed it with the Fleckstone paint.
this one is a little better
The latest bridge improvements.
Progress: