I have been making various fixtures and tools over the last few years learning the art of machining metal. I have completed several projects including a drill grinding & a tool bit sharpening jig, an adapter bracket to fit an old surveyor's level on my camera tripod, a punch and die to make oblong holes in the aluminum rail for track joiners and a rail bender. Other items include various track panel jigs. The major jigs and fixture drawings and photos are on pages 1 & 2.
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Jigs & Fixtures: A punch and die has been fabricated to punch two slotted holes in the rail for the rail joiners. It was designed by me to punch out two 5/16" long by 1/8" wide slots in the web of the aluminum rail for the joiner. The rail web thickness is .070". The joiner bolts (4-40) are just nipped up so that the rail can slide back and forth for expansion. It was very hard to make though. A lot of fussing getting the two punch pins to fit the die holes correctly but we made it. Now I know what die filers are for. I did my best freehand. I did stagger the punch pins and added some shear (5 degrees) lengthwise to them. I also had to add what is know as a stripper plate that holds the rail down so that when the punch is lifted up they come out of the rail. The first test without this resulted in the rail being firmly held by the two punch pins! Anyhow, it actually works and put the slots in the rail where I want them. But I don't profess to be a tool and die maker!! It also needs a lot more effort (read Force) than I thought. This is probably because the die clearance isn't quite correct. I'm sure an experienced tool & die maker could examine the scrap knock out pieces and tell me exactly how well I did or did not. If it works a thousand times I'll be real happy.
A rail bender has been completed and works well. It is a modified design from the late Frank McLean. I added a gear train to keep the fixed rollers from slipping.
Two track assembly jigs have been made: one adjustable curved for either straight, 40 to 80 foot radius curves. A turnout jig has also been constructed and is symmetrical so it can be turned over allowing the construction of right and left hand turnouts.
Three welded steel track gauges have been completed. Also completed are; a 4 foot adjustable level, a trench profile jig, a cross level for the roadbed tilt, and a roller. The roller has had wire brushes added to help keep it clean when rolling wet dirt and gravel. I use a large mirror for lining up the roadbed. In addition, many other little jigs have been made including a rail drilling guide, a rail cutting guide, a tie plate drilling guide, a slider plate drilling guide etc etc.