Finally had time to get some work done.
I got the new board and track finished and loosely leveled and laid into the closets, so Phase 1 is basically completed. Next phase is to connect the reversing curve trackage across the workbench to the new main line and Phase 3 will be to eventually build the liftout and connect it to the new board and the main layout.
For the new main line board, I used four of the 30" long Fastrack straight pieces and wired/soldered them altogether, so no continuity issues, and then glued the foam roadbed to the topside of the board. I had already cut a groove in the middle of the back of the board to hide the power wires. Where the power wire stops near the end of the board on the workbench side, I taped the wires closed and covered the end with liquid electrical tape - on the other (liftout) end, I cut the wire so there's about 12" hanging out to eventually connect to the Power Pole connectors on the lift-out.
I already have plenty of power around the reversing curve, so I don't need to extend the new power and feeders any longer than the board itself on that end - the new trackage across the workbench (Phase 2) will connect to the end of the board and will have plenty of power from the reversing curve power drops. I then drilled 1/2" holes through the foam and board into the groove on the underside of the board to run feeders up to the underside of the Fastrack to solder. Then cut small squares in the insulation of the new red/black power wire with a sharp Exacto blade and soldered 18 ga. feeder wires to the square cut-outs and up through the holes to the Fastrack. I covered those connections with liquid tape, also, and let dry before pushing the feeders up through the holes.
Once everything was soldered and in place, I taped over the groove on the back side with duct tape to seal the power wires in place and then stapled a few pieces of plumber's tape across the groove to keep the power wires from potentially falling out of the groove if the duct tape fails. I then screwed the track to the board at several locations. Before putting the board/track into the closets, I connected the excess wire on the liftout end to my workbench ZW transformer and tested the voltage all along the track and it worked great.
Next on to Phase 2 !
