2014-10.3: Building modular benchwork

20 Oct 2014

Average: 4.7 (21 votes)
17:10 - October 2014 Act III - Roadshow 2: benchwork (2014)

In part 2 of "The Roadshow", Trevor Marshall calls on his friend Pierre Oliver to help him construct Freemo-style benchwork for his S-scale Workshop modules.

Act IV - Back to the Basement: Subroadbed ...

Go to Act IV


What a great episode. I'm about to assemble benchwork for my own modules. This was very helpful.

Bntrainmaster's picture

Very informative. I've been working on rebuilding our club modules so we can cut down the set up/take down time by incorportating the legs onto each module and the 'lightweight' construction of these module you have shown has giving me couple of ideas.

Great video, do you have a source for the leg pockets?

tpmarshall's picture

Thanks for the kind words, everyone.

The leg pockets: The ones you see in the video were made by a local garage, which welded them for us. The European Fremo group has some lovely stamped ones, which are available only to members, I believe. Elsewehre, a Free-mo club might want to approach the European Fremo group about affiliate membership or somesuch, and perhaps find out about getting their own tooling done.


- Trevor

How do I get Pierre to come and visit me for 6 hours??  :)

tpmarshall's picture

Feed him.

I really like this series. Very nicely done and very informative.

Trevour - Great TV very helpfull.  You plywood framing has 1/4"  ply top, please confirm size of framing ply ? Looks like 4" x 1" ?

 Cheers..... John

 Chester UK

I'm actually part of the Credit Valley Freemo Group and have my own curve module with my dad and uncle jointly owning a three-piece yard module. I really like the techniques mentioned in this series as I think they'd be lighter and more durable than my existing curved module.

For the aluminum channel legs, are there any feet used on the bottom for stability? If yes, what are these feet?



tpmarshall's picture

Hi John:

Thanks for the feedback - I'm glad you're enjoying the series.

The plywood used for the framing is 0.75" thick, cut from the sheet to lengths 3.75" high. This number was derived from our module standard, which specifies a 6" high fascia at the module interface points. 6" minus 2.25" (2" of foam board plus 0.25" of ply top) equals 3.75".


- Trevor

tpmarshall's picture

Hi Blane:

The bottom of these legs have felt "floor savers" stuck to them - the kind that one attaches to the bottom of furniture legs. They're self adhesive. That said, I have plans to rip some wood plugs to fit tightly into the legs, to give the legs more surface area for sticking the floor savers in place. Right now, they're stuck only to the walls of the legs.


- Trevor

What kind of saw or blade guide was he using when he cut the 1/4 tops?  That looked slick.


tpmarshall's picture

Hi Greg:

It IS slick. That's a Festool TS 55 R plunge-cut saw with Festool guide rail. It makes clean, splinter-free cuts and while it's not the cheapest saw on the market - not by a long shot - it'll be the last circular saw you ever buy. I particularly like the digital motor on it, which brings the saw up to speed quickly, with no kickback, and then keeps the blade at a constant speed as it bites into the work.

Not for everyone, but Festool makes beautiful tools that will help you make better stuff.


- Trevor