The first thing I did was create my own template. I cut the the crossing out using Cadrail's
divide at Point tool and printed it using a one inch scale.
As with the turnout I cut the PC ties to length and glued them to the template.
Unfortunately things went downhill from here. I was attempting trying to find the simplest way to
build this thing. I soldered one of the tracks completely through the crossing
The theory goes as follows: All I'd need to do is cut a couple of rails and grind one end to a point so each point would
fit cleanly against the track. I'd then solder them place in place and use a cutting disk to cut the
rails and make......INSTANT FROGS!
As you can see from the picture, the center crossing was way off center and that was my undoing. I tried the same method
with all the other frogs.
All the while I was working on this I had the sinking feeling that this crossing was being built with
as much finesse as a butcher in a slaughterhouse. I hoped(and prayed) that if I filled the frogs solder and
skillfully wielded a hacksaw blade I'd end up with a working crossing. The result looked "Ok" but operationally
was a nightmare. I could get cars to roll straight through the crossing but my engines either derailed or the trucks
would go off in different directions. To make things worse, I didn't test my engines on the crossing until
I installed it on my layout.
The picture below pretty much sums up how I felt...
I ended up having to rip out the crossing (plus the roadbed underneath) and start over.
The main reason I used the method I described above is that I didn't feel confident in my ability to eyeball the two
outer rails first. I was concerned that I would have to keep re-soldering them because they would be out of gauge with the
inner rails and frogs. I thought I'd end up with a lot of kinks in the rails.
I spent a couple of weeks thinking/sulking about
my disaster and came up with this solution:
I fired up Cadrail and changed the line properties of the crossing by "Fattening" them up so that when the
crossing was printed the lines of the crossing were the exact width of the rail base.
I could then cut, bend, and solder the two outer rails and be reasonably sure about them being in the
correct alignment. This "Crossover by numbers" method has worked out much, much better.
I cut and ground each rail to size to build all the frogs.
I also wised up and tested this thing before installing it on my layout.
The results? Appearance: It looks pretty good(just don't look closely). Operationally: Uh...It works well enough
that I'm not in the mood to try a third time.