Hi Tom.
I did some more fiddling and was able to reduce the number of joints that don't connect to just 1 in each loop. I've tried every combination of RealTrax 5.5", 4.25" and 3.5" sizes and the best I can come up with is either a .16" gap or a .09" overlap.
That said, I can tell you that the default join error in the SCARM software I'm using is .079" and the software was designed for HO-scale track. The RR-Track software I also use at times was designed for O-scale track and has options to .20". If I change SCARM to .20", the joints connect. I have some RealTrax and while I don't have enough to configure a loop like yours, I'm confident there is enough "play" in the tracks for either configuration to work. Also, small gaps can be filled in.
And if you're going to use DCS as your control system, it calls for the layout to be broken into insulated blocks with separate power feeds to each block.
Photo 1 shows both gaps and the optional configuration.
Photo 2 is just a closeup of one side.
Photo 3 shows how I replaced 60 of the 10" tracks with 20 of the longer 30" tracks.
Photo1
Photo 2
Photo 3
