One of the worst parts of building a model railway has to be the baseboards. Bulky heavy nasty things. Woodworking was always my worst subject.
A few years ago I came across the Wandle Valley railway built in S scale by Mike Watts. His boards are brilliant. It consists of a honeycomb of thin ply within a frame which in turn supports a layer of styrofoam SM.
Since I needed multiple levels an open frame was required and the styrofoam wasn't appropriate. The solution was to blend Mike's honeycomb with Barry Norman's ply girder frame construction and use thin ply for the tops. The results can be seen below.
The three boards are each 59" by 29" allowing them to have sides added for protection when being transported while still staying inside a 5' by 2'6" footprint.
Legs are another big pain in the bum. Rather than fiddle about with bits of wood and cross braces, nuts, bolts, lengths of string, etc, etc, etc, I simply picked up a couple of pairs of Stanley folding saw horses.

The beauty of these are they have pre-formed holes in the top. These holes are perfect for mounting a wood spacers of varying thicknesses. This in turn allows me to adjust the height of the layout. With no spacer the board tops are 34" above the floor. By adding a spacer this height can be boosted to 42"
My woodworking still sucks but these are solid, level, and weigh in at less than 5kg each. Once the track and scenery are added the whole layout will still weigh less than 20kg. (not including the legs) All I need to do now is build the rest of it.


