With the initial distraction (:o) of creating the ZTM-440 modules in time for a recent train show now past (see General Notes), I've finally started to construct the individual sections that will make up the Forest End module.
Seen below is the first three sections partially completed. The two side rectangles are 36" in length and 20.25" in depth. You can see the Y-section sitting on the floor next to the Canyon Module, the 24" wide interface that will follow the Z-Bend Track standard at this edge whereas the interfaces to the other sections of the overall module will be custom in order to accommodate the track plan in the Forest Module introduction I gave in March.
As I've proceeded through the build of these first sections, I've revised my thinking on a couple of aspects of the original design. Firstly, I've decided to consider simplifying things by not starting any downward grade on the outside mainline until after departing the these side modules ... the outside mainline would then drop only roughly an inch to its lowest point (just over 18 scale feet) where I intend to run it alone side a typical Oregon coastal scene. I'll strive to keep the maximum grade to something comfortably under 2%. I may reconsider this again if possibly to reduce the grade a bit but if I do, I'll have to cut a bit into these side modules to begin the grades earlier in the run.
Another area that I'm still struggling with relates to the track interfaces between sections. Playing with the ZTM-440 modules where alignment between modules is readily accomplished with proper 90 degree secured tracks and a fairly robust track joining system, I've actually thought of emulating that solution with these sections. Alas, that would dictate that the layout be modified to arrange all of the tracks at each interface to be perpendicular to the module edge in order to be able to bring the sections together with joiners mating properly. While I plan to institute a reasonable vertical alignment feature using stock aluminum plates across section joints, I'm somewhat uncomfortable that I'll be able to hold tolerances horizontally for independent lines of track that sit at different angles to simply line up adequately for trains to run over them reliably. Just to reduce the operational risk, I may actually resort to going back to using Marklin adjustable tracks as we do in the Z-Bend Track standard between my sections - at least then I can continue to have the layout be more free flowing although it would introduce nominally a 4.5" straight section required in each line at each section interface.