Happy birthday David from down this way as well. You're only a young fella. We've got an osteoporosous TV ad here where this 40-50 Year old guy say's he was told he had the bones of a 70 yr old. I've been getting visited by Arthur Righteous just lately so went for a bone scan the other day, my Doc tells me mine are good for my age (74), so at least I can be happy with that.
Hand laying of switches is one of the things I'd like to do, have looked at the Fastrack jigs etc, quite attracted to their Twist Ties method which allows a certain amount of flexibility, i.e. either building them straight or curved as suits the application. The only drawback being that they really need to be built "in situ". Now you appear to be building yours "off layout" using presumably cardstock patterns. Do you use any point filing jigs to get your points, closing rails and stock rail reliefs accurate?
Hi Tootnkumin, Toot if that's ok?
Thanks for the BD wishes, it appreciated especially from your location, nice to know someone from Australia.
Well, time for more coffee and I'll get to answering your questions.
Say Francine, Flo, more coffee where did they go? Oh well, I made Chicken broth and a Burrito instead.
Toot you mentioned: 'The only drawback being that they really need to be built "in situ".' I'm not quite sure what your referring to unless you mean built in place? No they don't have to be and actually better if built on a template as the PC strips give them added strength as well as points to make electrical contact easily.
Again, I'm unsure about the twist tie method, which I assume is the way FT holds the PC tie strips in place while your solder the rails to them in their jigs?
Yes Toot, I do build my switch off the table for the convenience of working on them easily. I printed out the appropriate switches using an FT CD and then attached them, two of each switch, to a board and then covered them over with clear packaging tape. I then cut the various lengths of PC Tie strips from a phenolic board and attach them to the packaging tape over the various locations on the template. Actually I double up on the PC/tie strips in the frog area and even prior to the frog to give it extra rigidity.
As you can see on the back template I prebend the rail to somewhat match the the template. Then I'd cut the rail to length per the template or a bit shorter if I didn't need the longer lead in or longer tail rails or conversely leave them longer as needed.
Once you determine the length hold and mark the rail where the bottom inside web needs to be cut into the center >I< point to allow the Point on that side to seat against the center >I< section. Use a Dremel Tool with a cut off wheel grind the bottom web away till you get down center I but also the bottom web needs to be tapered back enough to allow the points to freely mate with the Stock [Outside] rail and the same applies to the top of the rail head to as it needs to be ground even with the center I too as well as tapered back slightly also.
Likewise the outside of the point rails need to be ground off so they will mate cleanly with the cutout in the Stock rail. A Dremel tool with a cutoff wheel handles this job fairly fast. The light rail does heat up considerably so a hand vise or pliers should be used to hold the rail while grinding on it.
When you get to where you want to make the angled pieces along side the point of the frog mark where you are going to bend them and use the dremel tool again with the cutoff wheel and cut in on both sides of the bottom web to allow this bend to be made easily. I don't think much if any of the bottom web needs to be ground off on either side of the point.
The point is made fairly simply by grinding off the inside web down to a slight point and doing the same with the mating rail so they come together to form the point you may have to test fit them while holding them over the template and taking off more back from the actual point till you get them to mate properly. Then clean the bottoms good unless you did that before and tin the bottoms as well as the PC strips unless done prior and solder them together and place them on the PC strips and and while holding down on top with a small block of wood solder them in place. Check your gauge to the outside rail and adjust the outside rail accordingly with your gauge.
Before doing any soldering the PC strips need to be cleaned good with something like a Bright Boy abrasive eraser to have true copper look to them as well as the bottom of the rails need to look shiny if using the weathered rail like I am and even nonweathered should be cleaned too to ensure a good solder joint. both the PC strips and rail should be tinned or a lite coat of solder applied where the two will be soldered together. This way when the two are placed together over each other and held in gauge and some heat is applied the solder should melt and solidify together.
Hope I didn't didn't confuse you with my explaination.
Tools you'll need:
Rail in the code of your choice, I prefer Micro Engineering weathered rail for it's prototypical appearance;
I also like their fine rail spikes
Some track gauges at least six to hold the rail when working with the 3' sections or even in doing smaller sections. I have Kemtron brass three point gauges but I don't think they are still available?;
Rail cutters of Razor saw;
Dremel Tool, I highly suggest the Cordless Dremel 10.8v Model 8000-03 At Amazon;
A set of HSS [High Speed Steel] or better drill bits
A soldering iron and medium thickness solder and flux;
A small pair of needle nose pliers
Track templates which you can make yourself;