Assembly

The 25mmx25mm softwood was marked and cut square slightly over length. Two 6mm diameter holes are drilled in the battens used to join sections. Starting on one side a 65mm wide section was drilled using a combination drill that cuts the countersink, clearance hole and pilot hole in a single operation and secured to the batten using a 3/4 inch countersunk No 6 crosshead screw. Use the square to ensure that the end is at right angles. Use the 3mm steel spacer to ensure the slot is the same width at each batten when affixing the three 100mm wide sections and the final 65mm section. Start with the ends then affix the intervening battens. Mark the excess of the battens so they can be trimmed to length using the jigsaw and mark each one with a number using a marker pen so they can be replaced in the same position following the routing.

Photos of Tools and Construction (Note how the roof trusses and joists influenced the design)

All of the battens were affixed to the corners prior to cutting the slots.

When the two main straights were complete the corners were bolted in place using the 50mm long 6mm diameter roofing bolts so the position of the slots could be marked. The battens were then removed and the slots cut using the jigsaw fitted with two blades to produce a 3mm wide slot.

All the edges were prepared with glass paper then the rebate for the slot cut with the router 1mm deep at 7mm wide. The finished sections were then affixed to the battens using PVA wood glue and screws in the previously prepared holes.

The barriers for the straights are made from 65mm wide 9mm MDF to provide strength to prevent the straights from distortion. The outside of corners barriers are constructed from hardboard cut in 65mm wide sections using the jigsaw. They are attached to the battens using the same screws used to attach the track surface. Additional support is provided by offcuts glued in place between the battens. They are affixed with the smooth side facing inwards.

When dry the screw heads are filled with filler applied using the scraper and left to dry before final sanding down.

Photos of the track during construction. Without the braid after painting and whilst fixing the braid.

Photos of the track when complete including the Controllers and relays.