@Hayfield
Many thanks John.
I sent a small G-clamp with the jigs for James to use on the corner of his table, you shouldn't have needed to kneel on the floor!
I don't think I sent matching front and back jigs, did I? I think the back was for an A switch and the front was for a C switch, so in theory the back-filed rail shouldn't have fitted in the front jig. I intended to send the C back jig, but it was a poor print due to problems with the filament, and there wasn't time to print another. I did send a finished C blade with the jig.
The end of the blade should be 20mm from the end of the jig. It's difficult to FDM-print a thin mark line. The idea is that you mark your own line 20mm from the end using a Stanley knife blade to scribe a thin cut across the jig.
I also noticed that the Jayo Grey filament seemed less resistant to filing than the eSun brown filament. So I shall be returning to that for the jigs. It's just a bit inconvenient that it's not such a good colour for the timbers, which means if you have only one printer you will be constantly swapping the filament over.
I tried to have the front jig with the rail tilted and the filing surface horizontal, but it made problems in the slicer software, and fitting the bolts through. Since all sizes use the same 17.5 degrees angle, the solution is to make a separate holder for the jigs which holds the jig at 17.5 degrees so that the filing surface is horizontal. I'm working on that, but I didn't get it finished in time. This is the problem all along -- there is so much still to do before the whole thing is really ready.
I noticed in your photo that you have the corner of the wing-nut fouling the file when filing the angle. It's important to turn both wing nuts so that the one on the low side is horizontal.
All this stuff will be written up in the instructions eventually. I did post some notes about using the jigs recently -- here they are again:
The jigs are used by clamping the rails in the slots with the M6 bolts, with enough rail protruding to be filed off at the required angle. The assembled jig can be held in a bench vice, or G-clamped onto the corner of a table through the large opening in each one.
Before finally tightening the bolts, check that both halves of the jig are flush with each other along the filing surface.
Use a good quality 2nd-cut engineer's flat file, and lightly finish with a flat 400-grit sanding block. The file will barely harm the jig, but the sanding block can do, so it is used lightly just to remove the filing scratches from the metal, so that the rails can fit snugly together.
Unless it is a very expensive file, it is unlikely to be dead straight. Looking along it you will likely detect that it is fractionally curved. If so, use the convex side for best results on the jig.
While filing, brush away the filings between every few strokes. The file itself won't harm the jig, but rubbing metal filings into the surface will do. Fully disassemble the jig after each use, so that you can remove any filings or other debris from the slots. The jigs will last for a great many filed rails, but being plastic, they need to be treated with care -- otherwise you will soon be printing a replacement.
1. The crossing jig makes both point and splice rails by turning the rail the other way up. They are opposites for the opposite hands of a V-crossing. The point rail forming the nose of the vee goes on the main side (MS) of the crossing.
After filing, the point rail should be blunted back to a width of 0.25mm (10 thou) at the tip by trimming with sharp snips and sanding smooth. When correct it should slide into the "A" chair and stop with the nose just on the far edge of the chair. Check it is the right way up and hand for the "A" chair, LH and RH chairs are handed.
The splice rail is not blunted back, but it's a good idea to remove the tiny feather of metal which remains from the rail web at the tip. The rail should slide up to the point rail and fit snugly against it.
The rails will only fit snugly if they have been filed using filing jigs exactly matching the crossing angle -- hence including the jigs in Templot.
2. The switch blade
back jig should be used first to prepare the backs of the blades. Again turning the other way up for the opposite side of the switch. The final tip of the blade will be at exactly 20mm from the end of the jig, so you probably want to start with the rail at about 19mm before filing. After filing, mark it at 20mm with a permanent marker.
Clamp the M6 bolt very lightly at the toe end of the switch jigs, just enough to restrain the rail sideways. If clamped too tightly it is likely to push the rail up away from the jig and prevent an accurate angle being filed. The heel end with the full slots can be clamped tightly to prevent the rail shifting.
3. The switch blade
front jigs are separate jigs for left and right switch blades. This "left and right" refers to the sides of the switch looking from the toe, NOT the hand of the turnout.
Insert the rail with the back already filed so that the mark is again exactly 20mm from the end. The jig is designed to accept the angle filed on the back at that rail position. That's the theory. In practice because of FDM printing variations you might find tweaking it a little forward or back fits best. Again clamp very lightly at this end.
The jig allows you to file across the head of the rail at 17.5 degrees, producing a sharp tip at the toe and leaving most of the rail foot intact. Make sure you have the correct rail the correct way up. The filed end will be sharp -- keep some Elastoplast handy.
If you mark along the rail with marker pen before starting, you can see where you have filed. The filing should run out at a filing length of 29.3mm for B blades, i.e. at 49.3mm from the end of the jig. Mark this position on the blade.
4. The final task is to make a very slight bend in the rail at that position, towards the centre of the track, until the filed top front running edge aligns in a straight line with the remainder of the rail. This is best seen by eyeing along the rail, but don't poke yourself in the eye with the sharp tip.
For the curved switch blade, do this first before curving the rail to match the template.
There are likely to be some burrs on the filed edges which can be fettled with fine abrasive paper. Do this on the bottom of the blades
before assembly, and
after assembly for the running top of the blade so that it blends in against the stock rail.
cheers,
Martin.