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June 1996 - Page 17


19 Al l the ties are now in place. The template helps to cut and position the ties correctly. Note the tighter tie spacing near the frog.

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20 Cut the electrical gaps in the pc ties with a cutoff disk. Fol low Figure 3 p rov i d ed l a st m o n t h to d ete r m i n e where t o place the gaps.

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21 Tin the tops of all the fixed pc ties with a tiny bit of solder. Remove any s o l d e r that b ri d g e s a n y of t h e electrical g a p slots.

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22 If you bal last the turnout before i n sta l l i n g the rail, make sure the template shows so that the rail can be positioned correctly. After the turnout is com pleted, ballast will be fil led i n a round the ties.

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23 Gently remove the base of the stock rai l with a cutoff d i s k. Do not nick the head or web of the rail.
careful when modifying the pc board ties. U n l i ke h a n d l a i d g e n e ra l t r a c k , t h e turnout does not need t o b e ballasted before installing the rai l . However, ballasting can be done, just leave the t e m p l ate show i n g between the ties a s a guide for lay i ng the rail (Photo 22). After the turnout is complete , finish ballasting. Lightly s a n d the tie tops with 2DD-grit sandpaper. Avoid removing the solder on the pc ties or splintering the wood ties. Do not re-color any ties at this lime. Begin by preparing the straight stock rail . Cut t h e rail to t h e appropriate length and round the rail-head ends slightly. The stock rails should always extend past the turnout by 3 "-4". Remove the base of the stock rail around the points. See Figure 4 ( last month) and Photo 23 for the location and method of this grinding step. Clean any burrs from the rail with a fine-toothed file. If the rail head is nicked, start over. Remove all the weath ering patina from the bottom of the rail with an a brasiv e rail-cleaner block. Next attach a feeder wire to the bottom of the rail. This wire should not be soldered near the points or frog. A h o l e i s dri l le d between t h e t i e s for the feeder rai l . U s i n g some b l ac k p a i n t o r a t h i c k p e r m a n e n t

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24 C o a t t h e b ottom of t h e ra i l wherever a floating pc tie goes. Use either paint o r a m a r k i n g pen with t h i c k i n k. Leave the rest of the ra i l bottom clean.
marker, coat the bottom of the rail at each l ocation where a moveable pc t i e w i l l be placed. This prevents solder from wicking under the rail and joining the moveable tie to the stock rail during a later step (see Photo 24). Coat the bottom of the rail past any pc ties with Pliobond as described in Part I . Immediately align this stock rai l over the template. When satisfied with the location, heat the rail directly above each pc tie. The previously applied solder will bond the rai l t o the tie. Heat and solder the entire stock rail as i l lustrated in Photo 25. Use a metal straightedge for straightness. Heat-bond the rai l t o the t i e s w here t h e P l i ob o n d w a s applied past t h e turnout. Re-heat and move w h i l e hot any rai l not perfectly in p l ac e . S ince other rail is gauged from t h i s first rail , ensure its location and straightness. The straight frog rail is laid next. Cut the rail to the correct length and round the rail head on one end. Grind the frog angle in the rail section with a c utoff d i sk in a motor tool. Grind slowly and check the angle often agai n s t the templ ate ( F i gure 4 ) . F i l e any burrs with a fine-toothed fi le. Note that the template shows that one of the two frog rai l s h a s the actual frog tip or point. T h e other

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25 Solder the straight stock rail to the fixed pc board ties. Si nce the ties h a v e b e e n t i n n e d p re v i o u s l y, o n l y a pply heat t o perform t h e soldering.
f rog rail butts a g a i n s t the first frog rai l . Clean the weatherin g pat i n a from the rai l b o t to m . A t t a c h a fee d e r w i r e . A p p l y P l i obond to rail areas outside t h e turnout. S older and heat-bond this rai l i n p l ace as seen in Photo 26. Use the three-point gauge as described in Part I to locate this rai l in relationship to the straight stock rail . The c urved frog rail fol lows t h e same p r o c e d u r e a s t h e o t h e r frog rai l j u s t described. Photo 2 7 shows this rail i n place. There is no feeder wire needed on this rail. The frog can be fi l led with solder behind the frog point as shown in Photo 28. Carefu l ly fi l e flat t h e t o p of t h e frog w i t h a fin e toothed fi l e . A l so remove any solder that wicks up the sides of any rail. Avoid lifting the rai l w h i l e soldering to the pc ties. Re heat and move any misaligned rai l . N e x t prepare the curved stock rai l fol l o w i n g t h e s a m e p r o c e d u re as w i t h the straight stock rai l . Use the three-point gauge as seen in Photo 29 at the frog and past the points. Make sure t h i s rai l flows smoothly through the turnout. Follow the templates and then eyeball the curve into perfection. O t h e r rai l s g a u g e from t h i s rai l . Use an NMRA flat gauge for a further check. The

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J U N E 1 996

M O D E L RAI LROAD I N G T 1 7

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