Making an operating outside Third Rail

I have been experimenting making operating outside third rail inexpensively. The enclosed diagrams show the basic idea. They are self-explanatory. Please don't ask for pictures. For the actual third rail I have experimented. Smaller 0 rail from micromark works well. I tried HO rail, but it is too soft and bends in the middle with use. At the end of a section the rails are champhored and bent down to permit the shoe to ride and not catch. I used machine bolts rather than screws. Adjusting the height is critical. Dimensions are not critical, but if you use a plastic tie and screw the bolt in you might crack the plastic. I made a long section of third rail with chairs and glued it into oversized holes in the plastic ties. You will have to sacrifice a section of track to get the extra tie pieces. You want an exact match with the existing tie. Hint the least expensive brass bolts  are easiest to file. from Home Depot  Thickness of the brass strip is not critical, but too thin is not a good idea. Use a jig to bend. For insulators I have used white plastic "Pony Beads" with a 4mm hole. Plastic beads can have the hole enlarged. Glass beads cannot.