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As many of you already know, we recondition lots and lots of track. The exact techniques of the cleaning and polishing we finally have done to a reasonable level. We even have significantly improved the methods of removing, cleaning and polishing the pins. Then resizing the tubes and reinstalling the pins.

 

Never a dull moment at TinMan's place, now we are looking for an efficient method of squishing(another technical term) the hold down tabs for the rails on to the ties. Thus far our method has been to cut a piece of steel, to the exact width of a new piece of tracks hoop size on the bottom of the ties. Then we put our piece of steel under the tie, hold the rail into place, and with a hammer and another tool (screwdriver works), tap the tabs down. Not very  efficient, and kinda hard with only 2 hands.  A pair of one of those wire connector crimping tools works well for the outside tab, but does not help the inside ones. Not too terribly concerned with the center rail, their usually pretty loose, and that's ok. They are a little fragile because of the insulators. 

 

Does anyone have a better way?

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Rob, when they originally made the track, they must have used exactly the same technique you suggested. It must have been a two step process, one to bend the tabs from vertical to at least semi horizontal and then the final Mandrel/press to finish the job. What ever they used it was strong enough to indent the rails themselves.

 

Servo guy, you have given me an idea.....more later.

 

My wife is trying to convince me there is more to life than train track. Some things women just don't understand!

When I re-bend, I square up sides first, then push the rail tabs down, while also bending the small "flap" that is the end of the tie, down and squared. You have to, just to keep it from bending up as the other tab is bent down. 

 Your die form(s) will be needed for a decent assembly line, even if it begins by hand.  A jig to secure your work is the next logical step. For now, a treaded form on a post in a vice.

 A jig plate could be made containing holes under the positions of the ties for each type of track. 1 jig, many positions. 0-27 straight, 0-27 curled edge, O, straights, shorts, etc., each type can have its own 3-5 forms(hint) mounted on dowels, to be inserted in the plates holes. "Track down, squeeze some, tap some, press some, smile some, then lift". Presses will speed this but you'll need a jig to be extremely efficient, and do three at once. And if it stays a hand process, you might be glad you did it anyhow. Having a couple "favorite", or "special made" sets of pliers wouldn't hurt.

 Doing it more by hand will reveal weak spots only felt by tools in human hands. 

For efficiency, you need to make a fixture. Make 3 of your steel blocks, drill a hole vertically through them, and screw them down to a board at the proper tie spacing. Countersink the holes a bit so the screw heads are below the surface. If you have a drill press, get a spare screwdriver and cut the handle off of it. Mount the screwdriver shank in the drill press chuck, put a track on your fixture, slide it on the drill press table, and press your tabs shut.

If you do not have a drill press, the track fixture will greatly speed up your hand closing of the tabs.

 

Larry

 

quote:
For production work, you really should be using a press with mandrels/tooling built to suit your need(s). It doesn't need to be fancy, just accurate and fast.



 

Hobby Horse makes (or perhaps made) a tool for tightening track. It will fit any of the commonly used Toy Train repair presses.

 

I use a metal block that fits under the ties, and a dull cold chisel.

Last edited by C W Burfle

Cw. Train Larry and Adriatic:  What terrific Ideas! I really like the hobby horse site, and will be ordering one of their presses, not only for the track, but also switch repair. Once I get that, I can see myself making the jigs you guys suggested for the various tracks. This is really going to make our work a lot more efficient, and be able to offer yet another improvement in our finished products. If you guys ever get bored, I would love to talk to you out here in Arizona about helping us in our quests!

 

Thanks guys! I really do appreciate this.

Thanks what a cool place! I have already sent them an email with my grocery list!

But guess what, you guys gave me an inspiration today, and I made another tool, will show it off after I am sure it works gooder (another technical term).

 

Servo guy you are right, a common ordinary slip joint pliers works way better than I would have believed. I kept on looking at the track trying to figure out why it worked so well. I finally noticed that what your system does is squish the tabs into the rails in a left and right method vs up and down.  Another benefit  I noticed, your system seems like it centers the rails perfectly as a side bonus. Quick and easy. I still think I would like it punched down, and I think as mentioned, I may have something for that. as an addition to yours, not instead of.

Thanks, I have tried many of the ideas and cannot believe how well they work. I am testing an idea that really seems to work great now, but it is a 2 step process, one just using a common pair of pliers, which not only initially tightens the rail, but also does a great job of aligning the track (space between the rails), this was servo guys suggestion.

This suggestion is really excellent when you have to replace a tie, trying to hold it in place while getting an initial grab is not easy, but the split pliers works great.

 

the second is doing something very similar to what someone else suggested by modifying a tool to tap the tabs down. Working on that now.

A little late, but here it is, TinMan's answer in combination with servo guy's suggestion of an old fashioned pair of pliers. Check out the px. This works great, it will not flatten 90 degree upright tabs, but that's what the pliers are for. Once they are semi flat, put one of the big metal chunks on something solid and give the other side a whack, and that rail will be super tight!  Anyone care to guess where these pliers came from? If no one guesses, I'll let you know in a day or so. My wife tells me I need a life other than my train stuff. Hmmm, oh well, what does she know!

rail to tie on track

rail to tie tightener

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  • rail to tie on track
  • rail to tie tightener

Hi Adriatic: I did try that solution, the problem, is it did not seem to lend itself for a high volume production that we are going thru. The most popular issue is one of the rails is either completely out of a tie, or 1/2 out.  Typically in an average day, we will  address this issue up to 10 times. Our procedure now is take the long nose, bend the outside pin straight up, reinsert the rail into the slot, squish the tabs together using servomans slip pliers, and finish up with the new tool. Entire operation less then a minute.

Figured, but if I don't tell you, I don't know that.

Those look like they will work well. Maybe better with careful grinding.

The spring should save some on cramps in the hands

There are smaller reinforced cut off wheels for die grinders. Even for a Dremel. A dremel might take a bit of time, a few disks, and a stone or two, but would create a well manicured slot and/or tips gripping shape.(lightest pressure, fast, avoid heat)

Last edited by Adriatic

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