I have the answer to some of your problems.
Rails failing to align Vertically and the Anti Derail switch fails you describe are usually due to non level benchwork.
Make sure all rails approaching a switch are dead level wit the switch.
I have a lot of Realtrax and it has been moved and rebuilt repeatedly over a span of nearly 10 years. It is mixed solid and hollow rail, more hollow than not.
Horizontal misalignment can be caused by no more than the pressure of your thumb on the rails, do not file them, bend them back in line.
Vertical misalignment I have never had.