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Session #: 18 Design Study: New Track Geometry

Join presenter Ben Fleskes as he explores new possibilities in LEGO train track design. This session highlights a wish list of features including flexible track lengths, improved switch geometry, and additional radius options. Discover practical steps for customizing tracks, from cutting and modifying existing parts to soldering and assembling durable mods. Learn how to create a versatile layout that complements existing LEGO pieces, ensuring playability and compatibility. Find the inspiration to take your LEGO train sets to the next level!

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Session #: 18 Design Study: New Track Geometry

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  1. Session #: 18Design Study: New Track Geometry 2003 BricksWest Carlsbad, California Session #: 18Presenter: Ben FleskesSunday, Feb. 16, 2003 @ 9AM

  2. Overview • Wish List • 9v LEGO train track mods • Final suggestions Ben Fleskes: Design Study: New Track Geometry

  3. New Track Geometry Wish List • Flexible track length • Improved switch geometry • More radius options • Different crossings Ben Fleskes: Design Study: New Track Geometry

  4. Criteria • Compatible with existing track • Maintain tie spacing ~ two studs between ties • 16 stud offset • Durable • Play well together – with other pieces Ben Fleskes: Design Study: New Track Geometry

  5. One Possible Answer:Track Mods 40S R 22.5 deg curve 40S R 11.25 deg curve Ben Fleskes: Design Study: New Track Geometry

  6. Or: 16S straight 4.35S straight Ben Fleskes: Design Study: New Track Geometry

  7. Why 4.35? 40S R 11.25 deg curve + 4.35S straight + 40S R 33.75 deg curve Ben Fleskes: Design Study: New Track Geometry

  8. Pretty darn close <0.1 S 15.9 S Ben Fleskes: Design Study: New Track Geometry

  9. Making it happen… What you need: • .080” x 080” polystyrene • Soldering iron • Solder • MEK (glue) • Hack saw • Exacto knife • Needle files • Flat file Ben Fleskes: Design Study: New Track Geometry

  10. Step 1: Start with a regular curve track Ben Fleskes: Design Study: New Track Geometry

  11. Step 2: Cut it apart Hint: A Dremel tool with a cut-off wheel works really well. Ben Fleskes: Design Study: New Track Geometry

  12. Step 3: Trim inside flanges Ben Fleskes: Design Study: New Track Geometry

  13. Step 4: Stage for assembly Note: the track with yellow bricks provides alignment 0.080” x 0.080” Polystyrene Ben Fleskes: Design Study: New Track Geometry

  14. Step 5: Begin Assembly Ben Fleskes: Design Study: New Track Geometry

  15. Step 6: Final assembly Hint: use a small blunt object to press the polystyrene firmly in place Ben Fleskes: Design Study: New Track Geometry

  16. Step 7: Glue Danger! MEK fumes are harmful! Follow all recommended precautions! MEK: Methyl Ethyl Ketone Ben Fleskes: Design Study: New Track Geometry

  17. Step 8: Solder Hint: solder top and sides of each rail Ben Fleskes: Design Study: New Track Geometry

  18. Step 9: File • File the excess solder away Ben Fleskes: Design Study: New Track Geometry

  19. Step 10: Done Ben Fleskes: Design Study: New Track Geometry

  20. Something a little more Complicated Ben Fleskes: Design Study: New Track Geometry

  21. Switch Mod 1: Cut the track Ben Fleskes: Design Study: New Track Geometry

  22. Switch Mod 2: Prep for assembly Hint: the remnant from a switch left can be used to modify a switch right. End of a curve track Ben Fleskes: Design Study: New Track Geometry

  23. Switch Mod 3: Reinforce and glue Hint: Use extra curve tracks to keep pieces aligned. Hint: Be careful not to glue the tracks together Ben Fleskes: Design Study: New Track Geometry

  24. Switch Mod 4: Solder and File Hint: Be careful not to dislodge metal rail when soldering Ben Fleskes: Design Study: New Track Geometry

  25. A sample layout Ben Fleskes: Design Study: New Track Geometry

  26. Another option Ben Fleskes: Design Study: New Track Geometry

  27. Or a real layout Ben Fleskes: Design Study: New Track Geometry

  28. What about curves? 104S R 11.25 deg curve 40S R 22.5 deg curve 56S R 22.5 deg curve 72S R 15 deg curve 88S R 15 deg curve 120S R 11.25 deg curve Ben Fleskes: Design Study: New Track Geometry

  29. What about a crossing? Ben Fleskes: Design Study: New Track Geometry

  30. Summary • Track mods can give you • Any length track you want • Very flexible switch track • Track mods can’t give you • Different radius tracks • No clear solution for another crossing Ben Fleskes: Design Study: New Track Geometry

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