1. Reproduction of any portion of this presentation including photos is prohibited without prior written authorization of OnDrew J Hartigan. roj2323@yahoo.com ALL RIGHTS RESERVED 2008-2011 Page Track Modification and Application By: OnDrew J Hartigan A presentation on the process of modifying Lego train switches to increase functionality and reliability along with a short slide show showing some of there advantages.

2. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Track modification Switches –Crossover –Half curve –Stubby –other Track –Straight –Curve –other

3. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Getting Started Remove metal rails!!! –Removing the metal will make modification easier and will also make the joint stronger The only time you shouldn’t remove the metal rail is track sections shorter than 5 studs

4. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 How to remove the rails Place a small flathead screwdriver in the small gap between the metal and wiggle it open.

5. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011

6. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Cut the Plastic Use a fine tooth saw. I use a Zona 1/2in 52tpi Item# ultrathinkerf$5.50Product No. - Kerf - TPI: 35-050 -.008in. - 52TPI35-150 -.008in. - 42TPI35-200 -.008in. - 32TPIhttp://www.zonatool.net/35-050.htmlhttp://www.zonatool.net/35-050.html

7. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Cut the Plastic

8. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Cut and trimmed for a stubby switch The donor track is from the opposite switch. Cut as shown and don’t forget to remove the stud on the switch!

9. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Build a jig This jig can be used for both the stubby and the half curve modifications

10. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Jig installed

11. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Final fit Using some plates install the short piece of track your splicing in and trim. Take your time and it will be a perfect fit. Next mark and cut a gap for the adjoining track tie to slip into.

12. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Reinforcing the joints You will need: Hand saw with a thin fine tooth blade I use a ZONA 1/2in 52tpi hobby saw X-acto knifes both a chisel blade and a pointed blade Glue I use zap-a-gap which is CA+ It’s primarily used in the model aircraft market but it’s the only thing I have found that works well on Lego 1_(1x6) brick 1_(2x2) plate A small screwdriver or something to poke the reinforcing strips in Part of a baseplate Spare brick to build a holding tool Chisel blade

13. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Cutting the reinforcement strips Build a jig to cut a 1x6 brick using a plate and a 1x8 piece of baseplate as your spacer. If you using a thin bladed saw such as the zona saw pictured this jig will allow you to cut a shim that fits perfectly under the rail. Next push the 2x2 plate onto a baseplate or brick plate and shave all 4 studs off. Be careful not to put your hand in front of the blade. Remove the plate from the baseplate and cut corner to corner.

14. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Gluing in the Reinforcement Glue in strip on outer rail and trim the piece sticking up on the other side Glue in the triangular piece you cut from the plate and trim so it’s flush

15. Reproduction of any portion of this presentation including photos is prohibited without prior written authorization of OnDrew J Hartigan. roj2323@yahoo.com ALL RIGHTS RESERVED 2008-2011 Page Rc track If you are modifying RC track congratulations you are now done! please note that unlike modified 9v track, which is incredibly strong when completed, modified RC track is not nearly as strong as unmodified RC track. Care should be taken with this track to ensure it is stored in a safe place and not thrown around.

16. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Installing the rails Tools you will need Track and the rails you removed earlier Dremel tool with a cut-off blade Rail nippers or a small pair of wire cutters X-acto pointed blade

17. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Marking the inside rail to cut Lay the inside rail in it’s rightful location and mark the cut location on the rail with the knife. It should be right around26mm from the edge. Cut the sides of the rail with the rail nippers and bend the rail up and down until it separates. Check for fit.

18. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Marking the outside rail to cut Setting the outside rail is a little different. Start by laying the rail on the track like you did for the inside rail. mark the rail where it overlaps the metal rail of the switch. DO NOT CUT. Instead make another mark about ¼ inch past the first one. This is where you will want to cut. Next go back to the first line marked and cut the sides only. Pinch the side flaps you just made and bend them off. It should look something like this:

19. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Fitting the outside rail Here’s where the Dremel tool comes in. Take the metal rail with the top flap and grind the side edges of the flap down slightly. Next bend the flap down to a 45degree angle. Using your needle nose pliers pinch the flap about 1/16 th of an inch from the bend and bend the flap back straight once. This will leave the flap slightly lower than the top of the rail which will let you slip it under the rail that is still attached to the switch.

20. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Reattaching the rails Using a pair of tooth free needle nose pliers pinch the rail tabs to the track. Take your time or you will mar the rails. CONGRATULATIONS!! You have now finished your first track modification.

21. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Using your new parts With the added flexibility of your newly modified parts you're on your way to making a more realistic,more reliable model railroad. No longer do you have to worry about S curves and the vast amounts of space wasted with unmodified switches and track.

22. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Unmodified verses modified Notice the “S” curve is gone and the over all required space is cut in half. S-CURVE

23. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Applications On the next few pages you will see modified track in all it’s glory. You will notice that not only are new angles possible but with a few slight modifications stock Lego switches are not only easier to use but a lot more fun and practical.

24. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Smooth transitions In this photo I used 3 half curve switches. This is really a simple demonstration of the advantages of custom switches but as you will see in the following slides custom switches really allow the user to create the well functioning layout he or she wishes.

25. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 45 degrees Anyone? This is something that is very difficult with unmodified switches but with a couple half curve or stubby switches this is really just a snap. Note only the switches are modified all other parts are stock.

26. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Switched Interloc This is really the reason I got into modifying switches. Again only the switches are modified. Further this can be made with either half curve or stubby switches.

27. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 A Junction Stubby’s gone wild! This really begins to show how custom switches broaden the possibilities of Lego train track. This junction uses 3 stubby switches, and 2 half straights

28. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Again all stubby switches but notice how compact this yard is. A Small Yard

29. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 An internal yard lead This is something that is absolutely impossible without modified switches. Using 2 half curve switches, 4 stubby switches 2 ¼ straights, 2 ¾ straights and 1 pair of parallelograms “for the crossovers” This setup shows how a few parts can really bring realism and functionality into an otherwise extremely limited system.

30. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 9v Double Crossover I first made this in late 2005. As of may/1/2008 I had built 2 of these for customers. They are the only 9v double crossovers I know to exist.

31. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 9v Three way Switch This is the second 3-way switch I’ve made. In this picture I chose to attach stubby switches to it to create crossovers, all though as you’ll see in the next slide I am by no means limited to this arrangement. Note only the switches are modified all other parts are stock.

32. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Doubble interlock with Single slip and 3 way note: the single slip is RC track and cannot be made in 9v

33. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Custom interlock

34. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 RC single slip switch I created this single slip switch in January/February 2008 mostly just to challenge myself.

35. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 A modification for clearance Ever wanted the switch throw on the correct side of the track or extra clearance for that big boy? This modification which only takes 20mins to complete, eliminates Clearance problems with the throw 8-wide and Longer rail cars need.

36. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Brickshelf account: Konrad Atrue double slip switch

37. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Converting RC track to 9v In general the idea is simple: add something conductive to the top of the plastic rail and presto you have 9v train track the reality is it works but one of the lego companies features of 9v track is it is self cleaning. Why is this bad? Lego 9v train motor wheels are made to rub the inside top edge of the metal rail ensuring conductivity while cleaning the rail. The problem is the wheels rub the rails and any tape on the rail will eventually be rubbed through/ away.

38. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 How long does it take for a train to rub through the tape? It varies on the quality and the type of metal tape. Aluminum tape is very conductive but it will rub through in an hour or two at best. stainless steel tape is better but you will still have to worry about it rubbing through. Solutions? Replace the tape often or find another alternative like replacing the rails all together. Converting RC track to 9v continued

39. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 brickshelf account:skaakoo RC track converted to 9v with metal tape and modified into a crossover. i’m not sure why it was done but it was well done

40. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Brickshelf account: Grunneger hand made track appears to be o scale track fastened to 1x2 plates with modified rail joiners

41. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 ME models metal rails This product was recently announced on Lugnet and other sites. Please attend the Train forum where iv’e been told you will get some hands on time with this product and hear announcements about other products. http://me-models.com

42. Unauthorized reproduction of any portion of this presentation including photos is prohibited without prior written permission of OnDrew J Hartigan. roj2323@yahoo.comroj2323@yahoo.com copyright 2008 - 2011 Thank you If you have any questions about modifying track please feel free to contact me via email at: roj2323@yahoo.com