To help un-clutter the layout with fewer risers and to prevent, long, 2x straight rails from sagging in the middle I came up with this little procedure for customizing tracks.

As you all know our layout has a lot of elevated track and because of that we had to use many extra risers where it was necessary to use half and quarter rails. This can add up many more risers and clutter up the layout. With the use of this procedure you can eliminate the need for those extra risers without any evidence they were needed. It can also be used to prevent the, long, 2x straight rails from sagging which we were having a problem with. The sag was enough to actually turn the motor switch off of a train running under the sag because it was too low. This especially happened if a train was on the sagging track at the same time a train ran under.

All that is needed are...

1/8” x 1/4” (3.18mm x 6.35mm) Brass or Aluminum Tubing commonly available at local Hardware stores and Hobby shops. None of the stores I visited had the longer lengths, nor did they have the aluminum tubing which is made. I ordered straight from the manufacturer longer lengths that I needed and bought the 12” lengths from my local Hardware and Hobby Center. Next time I order from the manufacturer I need to ask them the cost comparison between the two metals. Its important to use the 1/8” x 1/4” (3.18mm x 6.35mm) because it fits perfectly, width wise in the tabs and the thickness is less than flush so it fits over the risers like it was made for them.

Your favorite type of Super Glue

A rotary tool although you can get by without one it is so much easier with one.

Some type of weights. Heavy books would work also

A flat surface

Simple procedure...

For the long, 2x Straight Rail

On a flat surface and working from the bottom side of your track, cut the tubing to length keeping in mind to butt the tubing on one side and extend the tubing half way into the tab on the other end. With your rotary tool and a appropriate bit, rough up one side of the tubing and the area in the center of the track where the tubing will bond. At this point I like to use a rag with rubbing alcohol to wipe away any release agents from the plastic and any oils or grease from the manufacturing of the tubing.

Run a bead of Super Glue along the entire roughed surface of the track. Place the tubing, rough side towards the track, Press down and place you weights over the whole length to ensure that the track adheres completely flat with the metal.

When joining two rail pieces together follow the proceed above but add this step at the beginning...

Where the tubing will pass through the track joint, use your rotary tool to remove just enough of the lips so that the tubing will pass through and snap into place. Remove the lips flush with the track so the tubing will adhere smoothly through the joint and make a perfectly flat, custom track.

So there you have it. You can also make 1 ½ tracks, 1 ¼ tracks or 1 ¾ length tracks to eliminate even more risers if need be. This was just what I did, maybe you have a better idea or suggestions to make this procedure better or easier so let me here what you think and if you have any questions.