1. Switches
One Way to Hand Lay Them

2. Different methods Construction Location Components Free hand
Templates – commercial, homemade
Jigs - commercial, homemade
Location
On workbench – parts, whole
In place
Components
Points – hinges, bending
Frogs – fabricated, commercial, insulated
Many ways to skin a cat
Freehand – Just lay it
Templates - Good for “standard” apperance.
Prototype - advantage is tie spacing varies

3. Surprise! They all work!!! Trade offs
Time/learning curve vs. Money (jigs)
Skill sets
“Flowing” appearance vs.“Standard” pattern
Try different methods, find what works for you, nothing is “wrong’ nothing is “right”.
There are differences.
Jigs – buying a learning curve.
Basically lazy so I am going for the easiest and cheapest way.
Its not a race, if you can built one in 21 min 39 sec, good for you I’ll still take an hour or so.

4. What I will demonstate In place Paper template
Insulated, fabricated frog
Bending points
Rigid throwbar
Techniques adaptable to any frog number, curved or straight
This is my current method. Not the only method. It’s “A” method.
I like it because its flexible, adaptable and can handle about any situation.

5. Material and Tools Material Rail (Micro Engineering) Ties (Kappler)
Spikes (Micro Engineering small or micro)
PC throwbar (Clover House)
Ballast (Arizona Rock and Mineral)
Template (Prototype reduction)
Solder (Radio Shack)
Flux (paste, had it so long can’t recall where I got it)
I would suggest small spikes, micro spikes are really cool and I recommend them, but with caveat that they have a definite learning curve. I use several “tricks” to use them efficiently.

6. Material and Tools Tools Pliers/Spike pliers
Rail nippers/Flush cutting pliers
Files, filing block
Hacksaw blade
NMRA gauge
Soldering iron (25 and 100 watt)
Motor tool with cut off disk and brass wire brush
Belt/disc sander
Micro Mark spike pliers are not required, but I really like them.
Flush cutters Radio Shack
Minimal kerf, sharp teeth
100 W for rail to rail, 25 w wiring
Brass brush removes paint and weathering for soldering.
Belt sander quick work

7. Parts of a switch Common nomclementure
Don’t worry about the whole switch-turnout issue

8. Locate the switch Locate the switch Paste the template
Drill mechanism hole/slot
Ties
Glue
Trim, sand
Stain
Ballast (optional)
Station 1. Demonstrate the tie trimming. Ballast now keeps ballast out of the flangeways and points.

9. Stock rails Make stock rails Spike straight stock rail in place
Notch base stock rail (not head)
Remove weathering around guard rail
Spike straight stock rail in place
Spike diverging stock rail (curved) in place
Locate position from template and ties
Demonstrate colored pencil and ties strip trick.
Discuss filing block.

10. Hint : Shaping the rails
Filing Block
Cut slot with razor saw, put base of rail into slot and file the rail
1” Belt sander

11. Stock rails
I don’t notch the head of the rail.

12. Hint : Locating rails
Use flex track tie strip and colored pencil to mark where the rails go

13. Frog Straight frog rail File/sand frog rail
Spike to gage straight stock rail
Slide to gauge diverging stock rail
Slide the frog rails

14. Frog Diverging frog rail Tack solder frog rails File/sand frog rail
Spike to gage diverging stock rail
Slide to gauge straights tock rail and straight frog rail
Tack solder frog rails

15. Wing Rails Make wing rails Install straight wing rail
Cut and bend wing rails
Install straight wing rail
Spike to gage straight stock rail
Slide to check gauge diverging stock rail
Install diverging wing rail
Spike to gage diverging stock rail
Slide to check gauge straight stock rail
You can adjust bend in the wing rails.

16. Wing Rails 1 2 3 4
You can adjust bend in the wing rails.

17. “Check” gauge Finish the frog Fill frog with solder
Fill or specific bridges of solder.
Check gauge!
Fill frog with solder
Use hacksaw blades to clear flangeways
Check flangeways and check gauge

18. Points Cut points to approximate length File outside taper
Remove base and ball, but not web and inside base
File inside taper
Remove ball only, minimal web and no base
Optional bend
Use the gaps. Remember to make a left and right hand pair.

19. Points
Gauge Side
Gauge Side
Gauge Side
Gauge Side

20. Points Position the straight point Position the diverging point point
Cut to length, allow .010 to .020 gap to wing rail
Spike to gauge for straight stock rail
Position the diverging point point
Optional bend to match diverging stock rail
Spike to gauge for diverging stock rail
#5 -#6 maybe bend, #4 definite bend.

21. Throwbar Cut throwbar material Position the throwbar
Cannot be conductive/must be able to insulate
Position the throwbar
Use thin profile tie, matchstick or cardboard to space point from the stock rail
Put a dab of flux at joint between throwbar and point
Cut small piece of solder and put at joint
Solder point to throwbar quickly
PC board. Drill hole for the mechanism before or after. Cut slot in cladding before or after. Watch cladding on the bottom

22. Throwbar Position the first point against its stock rail
Position the second point
Use a tie, matchstick or cardboard to space point from the stock rail
Put a dab of flux at joint between throwbar and point
Cut small piece of solder and put at joint
Solder point to throwbar quickly

23. Guardrails Install guardrails Cut the guardrails
Make appropriate flare
Spike in place , using check gauge to wing and frog rails
If desired solder guardrails to the stock rails
Use hacksaw blades to ream out flangeways
If you have done a good job, guardrails are an after thought.
I like solder on each end to represent a pillow block.

24. Measure gauge between guardrail face and frog face
Guardrails
Measure gauge between guardrail face and frog face
Check guage!!!

25. Electrical Install feeders Install switch mechanism
Point rails and frog required feeders
Stock rails optional
Install insulating spacers in gaps around frogs
CA or epoxy styrene
Trim to match rail profile
Install switch mechanism
Hole in throwbar
Wire up frog polarity control
I like #20 solid core pretinned wire. Anything between #24 and #18 is OK. You can attach underside or to the side of the rail or to the base of the rail.

26. Wiring

27. Run Trains!!!

28. Resources Proto87 UP Industrial development : Prototype info
NMRA Standards : dimensions
Proto87
Kappler Mill and Lumber Co : Ties, scale lumber
Clover House
Hand Laid Track