Week 2: Dec 12, 2009

Crossover
The Delta Model Railway Club's HO layout is large, but to date only one module has a crossover on the mainline (it happens to be Stuart Wood's module).  My first store module will provide a second crossover of opposite handedness.  The club requires that turnouts on the mainline have at least a #8 frog.  Since I'm using Peco code 83 track and electrofrog turnouts, my crossover turnouts will be part number SL-E8382. 
Peco electrofrog turnouts can be used as-is right out of the package, however instructions are included for improving their reliability, by modifying them to minimize the possibility of a short circuit that could be caused by metal wheels bridging the gap between two rails of opposite polarity.  This modification is especially important because DCC systems are less tolerant of short circuits than multiple-cab analog systems, and we plan to operate DCC in the future.  The modification involves cutting two wires on the underside and soldering short lengths of wire between two pairs of rails.
When electrofrog turnouts are used, insulating rail joiners must be placed on both rails of the frog to prevent short circuits.  With a pair of electrofrog turnouts in a crossover configuration, a total of four insulating rail joiners must be used.
Before a turnout can be installed, a hole will need to be drilled beneath the frog for the frog power wire to pass through.  Another hole needs to be drilled beneath the throwbar for the turnout motor pin to pass through; this hole should be at least 1/4in in diameter.  Be careful when placing turnouts to ensure that the layout's wooden framing members will not interfere with the placement of turnout motors.

Replaceable Track Ends
Repeated module connections and disconnections will damage the track near the module ends.  I installed short, 3-inch sections of track at the ends to allow for easy replacement without having to rip up too much track.

I made a jig from scraps of balsa to help guide the drill bit in my hand drill to help ensure that the track spike holes are centered on the ties.  The jig is sized to fit snugly between the rails; it is shaped like the letter F when viewed from the edge.  The length of the jig is used as a guide for spacing the spikes.  Using a jig for this purpose is really overkill unless you are a perfectionist like I am, or have shakey hands.