This is another thread I will try to post back to as progress continues. Below is a very low-res raster image of a design I put together to be lasered into styrene.


A second design with add-on details is to follow. This piece has already been burned and is en-route to me, so I hope to be able to get started on this next week.

The keystoned arch "eyebrows" over each portal are not part of the design - they are in the graphic to show placement, but these will be separately-applied when the next sheet of detail parts is completed.

More to come later...

John

WOW!

Please tell us more about how you can have styrene laser-etched with brick detail? Who does this? How much?

Laser-etching/laser-cutting is getting more prevalent, but it's still rather expensive. This piece, without the add-on details coming in the next design, will end up running me about $60.

This does not include all the time I spent on the design itself, nor the software I had to purchase to do vector graphics.

Here's a mock-up of the multi-layered side-hall front:




I had started a thread about my third skyscraper, which used laser-etched and laser-cut black acrylic for an all-glass effect. A search in the archives looks like it's been dropped.

I'll post more as the design progresses, and the pieces start arriving. This will be a rather long-term project...

Cheers,

John

I remember reading the skyscraper thread, but I didn't realize that the laser process could be used to cut bricks and stones.

Will you be marketing the Union Station as a kit?

No. My hunch is that the market is going to be far too limited to do a large run. Although by no means is it going to be an exact scale version, this design is unmistakably for Washington DC's Union Station, and won't translate well into GCT or others.

Another issue is size. The first image above shows the front face of only the main, center building. It alone is over 20" wide. The two side halls will be 16" wide each, and the east and west wings will each be 8" wide. That yields a grand total of over 5.5 feet in width.

You could just get the main building, and either omit the side wings altogether, or do much more reduced sizes on them.

If interested, contact me off-line (john2@pixelsplash.com) and I'd be happy to quote anyone for exact pieces. If there's enough interest, we will certainly get better prices.

Cheers,

John

John, That looks and sounds like the best project yet. Please post some pictures when you get the parts in.

Ed

The first sheet of pieces is in. This comprises pretty much the design in the first post above.

They are beautiful. There was a thin film of dust all over the surface, so I cleaned all the parts off with a wet sponge.

The main facade is a large piece, and since it's 1/16" thick styrene, it bends. So I framed the back with 3/8" square wooden dowels.

I am now in the process of attaching the add-on parts from this first sheet. Next week, I should be able to get the second sheet, which has more of the detail parts - including the "eyebrows" for over the portal arches, the matching keystones, and the six inner hallways for each portal.

Wish I had a camera - mine's broke. We were going to get a nice new Canon (Digital Rebel), but those funds went to the tsunami cause.

When my Dad and brother come over tomorrow, I will see if I can get them to take some pics for me so I can post them.

So far so good!

Cheers,

John

Here's the second sheet with the rest of the detail pieces.

The reason there are so many "eyebrows" is that I am getting enough cut to do the back side, and both of the interior walls as well as the front face.


The six bricked rectangles are the sides to the interiors of the arched portals.

John

John

I know for a fact Tony Lash is looking for a DC Union station for his layout. He has reserved a 6' by 6' area at the end of his passenger yard waiting for it. I will call him and let him know about it.

I couldn't find anyone willing to do it and there it sits.

Jamie

Several folks have now emailed me, so maybe there is more interest than I had presumed. So let me provide some more disclosure so we all know what we're getting into.

This is nowhere near a full-scale model of the real thing. A 1/48th scale version of Washington DC's Union Station would occupy a footprint larger than most of the bigger layouts in the O-gauge hobby. The length alone would exceed 18 feet!

Here's a photo of the main, central building of the real thing:


Compare that to the CAD drawing of my main building front:


You can already see some of the liberties I've taken in selectively-compressing and also flat-out elimination of major features. The most glaring example of this is the fact that my model will only have 4 columns in front, whereas the real thing has 6 (the two flanks have been removed to get the overall size under control).

Here's some work-in-progress shots of the columns with the statues:





I have never been able to find really good replicas of the Roman Centurions which adorn the station inside and out. These are the closest I can find to date.

Lasering does not work like casting plastic pieces. In casting, you must make a master piece and then make a mold from that, and then make copies of that exact piece from the mold. Changing the master and re-casting the mold is very expensive.

With lasering, you can change the design pretty easily from one copy to the next. If you or anyone is interested in somewhat smaller pieces, or perhaps with less detail etched (most of the cost is in the detail etching), we can do that too.

Let me know if interested. The main central building, as I have designed it for myself, is to occupy a 20.338" x 16" footprint. You could make your own side-wings of different designs (heck, you could even use our West park Tower building templates and cut them up to make wing/sidehall faces of almost any size).

I'll try to get some more pics up of the actual pieces. I'm relying on other people for my photography now...

Cheers,

John

John,
I admire you for taking on such a project as this.
I went through Union Station for the first time this summer and was completely bowled over at the beauty of the place.

Look forward to seeing your progress.

Johnboy-

If you have carved those columns, you are truly talented! I will be monitoring your progress with great interest. Great job so far!

Thanks gentlemen. The columns are not carved by me - they were purchased at Michael's craft store, in their wedding-cake decorating section. They are for holding up the upper tier of fancy wedding cakes.

They make tall ones (~7" high) and shorter ones (~5" high). Funny thing is, they are near-perfect for use in a Washington DC Union Station model. Anyone serious about a project like this should go get a set - they are not expensive.

Because I knew I wanted to use these, they ended up determining the final dimensions of the model. It took some fenagling, but I used the software to scale the design so that the columns fit perfectly along the grooves etched for the add-on moulding detail, which connects to the tops of the columns.

A picture paints a thousand words (at least!) - so I hope to be able to post some pics in a few days which will make this more obvious.

Cheers,

John

Here's a mock-up of the whole front:



The side halls each have only 5 arch portals; the real thing has 7.

Another thing I have not yet begun to really play with is how to do the roofs. The real thing has a very elaborate romanesque barrel-vaulted ceiling and roof line. At this time I am not planning to replicate this for my model, but I may change my mind by the time I get to it. I'm just not sure how to get an etched piece of styrene to bend like that, and to adhere to side pieces in a permanent way. I'll ponder this some more...

John

This message has been edited. Last edited by: JohnBoy, November 09, 2005 11:27 AM

John,

I have some rolled aluminum 1/4 arch pieces that I plan on using for a station platform cover. even though the arch is only about 90 degrees, you can still uses it to cover a platform, I think 180 degrees would actually look bad.

I am not sure exactly what it is from since someone just gave it to me out of their garage, but I suspect it is either some decorative gutter cover or possibly a part of a decorative pillar cover for a front porch. You might try a siding company for something like a pillar cover.

Ed

John

If you want to roll the roofs NJ Sullivan in Sterling can do it for you They would use a heavier gauge metal and will do a nice Job.

Have you considered a front only? Like the Ameritown Fronts.

Jamie

Jamie - indeed - what is shown here is just that - fronts only. The side pieces will come later, and I also intend to get a sheet or two of plexiglas engraved and cut with doors, palladian windows, etc.

This will be a big project - in every sense of the word.

Cheers,

John

Finally, all the detail pieces came in. The first sheet I screwed up and made them all too large, but the second time was the charm.

All pieces were first painted with a limestone/sandstone color. Then I made a very thin India ink & alchohol wash and weathered the surfaces, mostly just to get the brick pattern and other etchings to show up a little more.



The ledge mouldings are all just strips of basswood cut to size and glued on. You can see the crown moulding I have only just started today around the far left arch portal. I'm hoping eventually the ceilings in each arch portal will be barrel vaults, but I'm not sure yet how I'm going to swing that.



Can't wait to get the next sheet, which will be one of the two sides to the main building.

Cheers,

John

John

That is very nice! Keep us posted.

Jamie

More progress shots:

Overhead, showing the portal inner walls:




This one shows a little better the finished cornices of the crown moulding under the arches, and the base moulding:



And another full-frontal:


BTW: these latest are all taken with the Fuji Finepix S7000. A fantastic camera.

Cheers,

John

Wow! Think I recognize that person under the arches. She tried to hit me up for cash and cigarettes. Seriously, John, that is an awesome model.

------------
Union? Yes!

quote:

JohnBoy posted...

I had started a thread about my third skyscraper, which used laser-etched and laser-cut black acrylic for an all-glass effect. A search in the archives looks like it's been dropped.

That's what's sad about the majority of "educational" postings (I can't think of another appropriate term) that Forumites spend the time to post, for everyones use and enjoyment. They're deleted and gone forever.

It makes you wonder... why bother?

I realize the maintenance and storage of all the posts can be labor and cost intensive. But, the database of useful "0" Gauge model railroad knowledge should be preserved, somehow. Isn't that why we return again, and again... to read what posts can help solve are model railroading dilemmas?

I can recall the heated debate regarding a fee-based use of the Forum. Thankfully, sponsors came to the rescue to maintain its "Free" status.

I would probably subscribe to a fee based "OGR Forum archive", if I knew that all of the postings would be preserved for future use.

What say you?

I wish I could review John Boys orginal posts and photographs of the skyscraper he posted. It was truly a work of art. But, I guess I can't, now. Maybe it can be posted again, for others to admire.

In any case, JohnBoy... your latest envdeavors are truly amazing!! Thanks for your "work-in-progress" updates.

.

DC Union Station has many memories for me, but the main one is of a very large model railroad on the second or third floor in the front of the left wing. It was built and operated by a club in the 40's or 50's and I am not sure what gauge it was. Another memory was of the run-away engine that crashed into the lobby around the mid 1950's.

I realize it's not the same one that existed in the '50's, but I found this info from the D.C. Pages.com website.

quote:

Norwegian Christmas at Union Station has become an annual tradition in Washington D.C. For the 5th time this Norwegian cultural festival offers a wide range of events including concert, exhibits, bazaars, workshops, food demonstrations, travel information booths, a large model train display and more

...and

Union Station Holiday Activities

quote:

Holiday Model Train at Union Station
Through Jan. 9, 2005, 10 a.m.-7 p.m. daily
Union Station, Washington, D.C.
When the winter holidays roll around, Union Station breaks out a 32x16-foot train set, one of the largest Scale-G trains in the world. Sponsored by Norway, the landscape is meticulously designed to recreate a Norwegian setting, complete with ice skating rink, church and toboggan sled ramp

,

AlanH - it is disappointing sometimes to see threads get lost. But the sheer volume of threads, combined with still-flakey internet technology and the periodic software updates that are necessary, well... sometimes stuff just gets dropped, plain & simple.

When I see a thread I know I will want to read again in the future, I bookmark it, and when it looks like it has run its course, I save it to my local hard-drive.

In the case of photos, you can actually right-click the image, and then choose "Save-As" (in most browsers), and save the pics to your local hard-drive, and then you have them forever. Oof course you'll want to burn periodic backups to CD-ROM, as even hard-drives are temporary creatures.

Re: the glass skyscraper, I will certainly re-post those images, along with some of the specifics about the lasering process and construction.

Eventually, all of this stuff ends up on my personal website (see link at the bottom of all my posts).

Cheers,

John

That is one wonderful work of art. Just goes to show what can be done with modern CAD software and laser etching.
I've decided on modeling Pittsburgs Union Station for my layout as it can be sized to fit and it can be build from pine, masonite and artboard.

quote:

AlanH - it is disappointing sometimes to see threads get lost. But the sheer volume of threads, combined with still-flakey internet technology and the periodic software updates that are necessary, well... sometimes stuff just gets dropped, plain & simple.

Yes, I can agree with you, in part.

However, the technology exists and, has been used for quite some time... known as "Data Farming" (and, other terms) which Hewlett Packard and Google are quite proficient, in "preserving" Internet content.

Every single post on this Forum can be archived!!!

It all depends on those that are willing to do so. Yes, there is a cost to this endeavor.

But, it is a lot cheaper than you think!!!

.

One way to prevent threads from being lost is to keep them current.

NH Chris

Uh, WOW! That puts my South Station model to shame. We almost need a photo gallery or thread of model of the major city stations. I know there are several of Grand Central, but this is the first DC station I have seen.

Amazing. I'd love to get that kind of detail on my south station, without the cost...

It sounds like you are using vector graphics to send to a CNC shop to do the laser etching, is that correct? I would imagine you get some deal on the etching doing it for other of your products.

You should produce some of the DC stations for those who have emailed you. Just having anything on Tony Lash's layout would be very cool. I know someone used to build South Station models, one of which ended up on Marty Fitzhenry's layout which ended up in OGR.

If you ever want to do Boston's South Station, let me know...

Maybe you could do a "Famous Stations" line - Grand Central, Boston, Penn Station, Chicago, DC, Philadelphia, etc. Not high volume, but certainly you could sell some.

quote:

One way to prevent threads from being lost is to keep them current.

... BUSTED! ...

Yes, I have been negligent in keeping this one updated. This week I am going to order one of the side pieces in order to get started on that.

Dave - you got it right - simple vector graphics sent to whatever laser shop can do it for the lowest price. Just to be clear: I get no special discounts. Everything I do is too low-volume for that. And lasering ain't cheap: the relatively simple side pieces I want to do next are $32 each, before shipping.

As always, if anyone is interested in obtaining some or all of these pieces, let me know.

Cheers,

John

Below is the CAD plan for a side wall to the main, central building.


The arched opening will be internal - opening up the main concourse to the side halls. These internal gateways from the main concourse to the side halls will have a "bridge" with columnar supports and statues, to try to capture a little of the feel of the real station. These are shown in green lines below:


My model is of course a drastic reduction and simplification of the real interior:



This piece (just one of the two needed) has been ordered. Hopefully I will get it before Father's Day, and I'll post pics of the process.

Cheers,

John

This message has been edited. Last edited by: JohnBoy, November 09, 2005 11:23 AM

What sort of vector-image program did you use? I'm starting to experiment with vector artwork, thanks to an (older version) application I found on a computer-magazine coverdisc

---PCJ

Johnboy,

This is really well done! It is nice to see a modeler.
It is even nicer to see a prototype modeler with a unique angle at getting what he wants!

More than Congrats!! I too want to do a depot...The Union Station in Denver Colorado!

Rick Trinkle

JohnBoy,
a ways back you pondered how to construct the barrel vaults. Perhaps a grid in styrene, would have to be made up, which would then be heated in hot water and bent around a curved form. The heavier structural elements, as in the recent protoype pix, would then be added to flesh out the detail.

The large barrel vault of the main waiting room could be similar. The trick would seem to be able to cast or create a one piece grid in a flexible enough plastic that could then be bent as mentioned above. Then the remaining details added. My guess is that its too difficult to do a one piece in styrene, as it needs to be injection formed?

great progress!

RailRide - I'm using Adobe Illustrator, I believe the second-to-latest version. My wife is a whiz-bang with this and other graphics programs, so I stuck with it to tap her knowledge (which has paid off several times already!)

Trinkle-Trains - thanks so much! I hope to be able to make more progress and get more pics up here.

Chris - you are spot-on. I do plan to use the boiling water technique to get styrene to bend into barrel ceilings. I think (hope?) this will work for the smaller ceilings needed inside the portals.

But I'm sure you're right about the big ceiling: it will need a much more sophisticated solution. I may very well end up not doing a barrel-vault for that, at least not until much later.

Thanks everyone!

Cheers,

John