... have posted here before, but not for several years. It is much easier to file a vee after assembling it. Even easier if you use a disc sander. This shows how a vee can be constructed to any angle matching the template, without needing filing jigs, and finishing with solid metal at the nose. I have greatly exaggerated the crossing angle for clarity. The rails are shown in cross-section along the rail -- yellow shows the rail head and foot, orange shows the web of the rail: 2_060749_540000000.png Make sure you have both rails the right way up. Bullhead rail has the thicker part at the top. A is a prepared piece of rail with the end bent to the crossing angle, or slightly less. Allow a little extra on the overall length. Then file it as shown to become the splice rail. Make another one of the opposite hand as B, to become the point rail (nose). No need to file the end yet, but file a notch in it to receive A as shown ...

... I will get all this into the Templot Companion eventually. It is much easier to file a vee after assembling it. Even easier if you use a disc sander. Below shows how a vee can be constructed to any angle matching the template, without needing filing jigs, and finishing with solid metal at the nose. I have greatly exaggerated the crossing angle for clarity. The rails are shown in cross-section along the rail -- yellow shows the rail head and foot, orange shows the web of the rail: 2_060749_540000000.png Make sure you have both rails the right way up. Bullhead rail has the thicker part at the top. A is a prepared piece of rail with the end bent to the crossing angle, or slightly less. Allow a little extra on the overall length. Then file the end down to the web as shown to become the splice rail. Make another one of the opposite hand as B, to become the point rail (nose). No need to file the end yet, but file a side notch in ...