One of my other hobbies is model railroading. I'm planning to construct a portable HO scale layout with self-contained lighting that I can easily move and possibly take to modeling exhibitions. It would consist of two modules, wach one about 2' deep and 5' long. The best construction scheme I've seen yet for such a module is:
I think it's overbuilt. I've seen similar modules built of nothing more than artists foamboard doubled up for strength. I'm not quite willing to go that far, but would like to use 1/8" birch or maple plywood.
My major sticking point is the 10" radius arc from the upright to the upper horizontal arm. I'd like to reduce that or even eliminate it if feasible. The only weight on the outer end of the horizontal arm would be light fixtures, either under-counter fluorescents or low voltage halogen floods, and possibly a roof which could be foamboard. Somewhere around 2-3 pounds per former or less.
My reason for wanting to eliminate the gusset is to increase the height of a vertical backdrop and make it possible to curve it around the outside end of each module. The original calls for a backdrop curved under the gussets with a 90 degree corner at the ends.
So what do you folks think? Is the curved gusset even necessary? If so, can the radius safely be reduced? There must be some way to calculate the deflection of the upper arm under various loads with various, or no, gusset shapes and sizes.
I've discussed this on a modeling group and one person suggested the radius could be reduced to 6" or a triangular gusset 4" on top and back. Others weren't so sure. So I decided to post here where a lot more of us have built a lot more stuff with plywood.
All help greatly appreciated. Thanks in advance.