This document describes the design and construction of a portable Lionel train layout that fits in a custom hard case measuring 61" x 24" x 5.5". The layout was designed to be easily portable and set up by one person in small living spaces like under a bed or in a closet. It uses Lionel FasTrack for its stability and larger 32" radius curves. Scenery includes a hill, rocks, lake, buildings and figures to make the small layout feel more expansive. The innovative 3-piece hard case design allows the two layout halves to securely connect without any cuts or joints in the track.

1. Lionel Layouts
In a Box

2. Objective
Create a portable Lionel train layout that could be carried and set
up by one person and store underneath a twin bed or in a closet.
Background
The inspiration for this project was a family relation and longtime
rail fan who was residing in a nursing home. I had become the
custodian of his train collection because in this situation, there
seemed no way around the oft-heard lament that, “there is no
room for a model railroad”. It seemed a shame to me that
something capable of providing great joy would be denied
because of a lack of imagination. Surely a portable, suitcase-
styled model railroad could be accommodated and permit him to
run his impressive collection of 1950’s vintage equipment. The
only problem was his equipment was Lionel O-gauge.
Design
There were many constraints on this design beyond the
challenge of working in O-gauge. Fundamentally, it had to be it
had to be rugged, reliable, and simple for anyone to set up.
Additionally it had to store either vertically in a closet or under a
twin bed and be easily lifted by one person. From these
requirements I set overall stowed dimension limits of not greater
than 66” x 30” x 6”. The go/no go test for the project was to
determine what kind of layout would fit within these dimensions.
I chose Lionel FasTrack because although it had a larger (32”)
radius curves than 0-27 track, it provided greater stability and a
more secure connection between track segments. The larger
radius permits the use of true O-scale in addition to O-27
equipment and provides a somewhat grander sweep to an
admittedly limited mainline. Buying Lionel’s NYC Flyer kit
proved to be the most economical way to obtain all the required
track work plus the transformer and a complete train to boot.
With the track plan established, the case could be precisely
sized with outside dimensions of 61” x 24” x 5.5”.
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Lionel Layouts
In a Box
Lionel Layouts
In a Box

3. Construction
Clearly the case would be key to the project. A custom wood box
was an option, but heavy. Guitar cases seemed promising, but
my constraints were too specific, so I contacted some custom
case companies to see what was possible. To my surprise,
several companies were able to quote custom cases fabricated
from a variety of materials, at reasonable prices. Turns out the
music industry creates a demand for odd cases to enclose all
the equipment needed to support a road show. By using
common hardware and trim components they could cut extruded
plastic sheet of any size to order and assemble a custom case
for a few hundred dollars. The largest obstacle was making the
case able to fold flat in such a way that the track laid in the two
halves would be able to smoothly join. With a hinged case, this
would have required several cuts in the base, complicating the
joint, weakening the structure, and driving up costs. Instead, the
key innovation was to use a three-piece case in which the two
layout halves are closed by a short detachable end cap. This
solution eliminated the difficult hinge and permits joining the two
halves without the need for a jumper track, since the track on
each half can project into the end cap. Furthermore, by
alternating the orientation of the latches, the same hardware
used to close the case is employed to lock the two layout halves
together during operation.
To provide an adequate roadbed for the track and sufficient
rigidity to prevent the scenery from flexing, a 3/16” thick plywood
sheet was installed as a foundation to build on. With the case
now in hand and the track plan determined, the vision for the
remainder of the layout came clearly into focus. One side would
have “high terrain” features in order to provide storage for the
locomotive and rolling stock; the other side would necessarily
have “low terrain” features. This translated into a hill and a lake.
2” foam insulation board was used to create the hill and the
rocks were cast with Woodland Scenics Foam Putty in standard
rubber molds. Though somewhat expensive for applying to a 1 of 6
Lionel Layouts
In a Box
Lionel Layouts
In a Box
Layout during construction

4. large area, Foam Putty produces much lighter rock molds than
traditional plaster casting. It’s important to be sure the mold is
clean and coated with a mold release agent. Once filled with
foam putty, it must be allowed to dry completely, a process that
could take a day or two, before carefully peeling back the rubber.
The result will have all the detail of a plaster casting with a
fraction of the weight. These castings were glued into place with
acrylic Liquid Nails. After they had dried, some additional Foam
Putty was rubbed into the seams with a finger to blend them into
their surroundings.
Epoxy resin has become the common choice for modeling water,
but with such a large area to cover, the weight and potential for
cracking was a concern. I decided, instead, to use an old
technique that works well with larger scales, namely painting the
smooth side of a suspended ceiling lighting panel. The faceted
side provides a good illusion of wavelets in this scale and the
panel guaranteed uniform flatness and maximum thinness to
accommodate the raised storage hill in the opposite half of the
case. The beach was an afterthought to fill a corner but again it’s
the painting that creates the illusion and a few whitecaps go a
long way.
To create the pastures, felt was glued to the surface and then
teased with a wire brush. The wood structures were scratch-
built and weathered with a strong India ink wash. The station
house was designed to modestly cloak the transformer, which is
mounted to the plywood base. It is hardwired to the layout,
making setup as easy as taking off the bottom piece of the case,
locking the two halves together and plugging in the transformer.
The judicious use of figures to create mini-scenes can make a
small layout feel much larger. Lots of activity at the station
distracts from the extreme curvature of the platform and makes
the empty portions of the layout feel further away . Even within
this scene, the boys with their bikes forms another sub-story,
adding storytelling depth. The lone figures fishing and at the
beach emphasis the emptiness of the scene, making it feel
larger. A little experimentation can get just the right feel. 3 of 6
Lionel Layouts
In a Box
Lionel Layouts
In a Box
Testing storage and portability
The connector cap

5. 4 of 6
Lionel Layouts
In a Box
Lionel Layouts
In a Box
Scenes along the rails

6. 5 of 6
Lionel Layouts
In a Box
Lionel Layouts
In a Box
Scenes along the rails

7. 6 of 6
Lionel Layouts
In a Box
Lionel Layouts
In a Box
I hope this project is an inspiration for those who
feel their railroad dreams, especially if you dream
in large scale, are precluded by lack of space.
Large scale trains have an appeal and a
practicality to children and seniors alike. Whether
it’s in children’s hospitals or nursing homes, or
anywhere space is an issue, this article is proof
that the suitcase-sized Lionel layout isn’t a
contradiction in terms. With a little precise
imagine there is always room to realize the joy a
model railroad can bring.