Indiana Live Steamers, Established 1957

Phase 3 Construction

Rail Joiners

Indiana Live Steamers has recently started construction of "Phase 3" of our track plan, which will add almost one mile of track, a trestle, and a complete block signals system to our land lying west of the (north-south) road thru the middle of our layout. This will involve about 3000 feet of new track panels, and our first large use of plastic ties to lay the rails on.

Phase 3 The area at the top of the picture, to the right of "Walnut" is the proposed route of the new construction. The loop in the lower left corner of the map is the location of our tunnel, which will be built as Phase 4.

The rail joiner we decided to use is simply a 4" long piece of aluminum bar stock, 3/16" thick by 5/8" wide. It need two corners rounded off to a 5/32" radius, then gets four 1/4" holes drilled on 1" canters. Each rail end will have two matching holes drilled, then one rail joiner, or "fish plate" is installed on each side of the joined rails, and secured with four #8 screws and nuts. We'll need a minimum of around 1400 "fish plates", and two members have voluntered to make them. Will probably need another thousand or so to rework older sections of the existing track.

Cutting the bar stock on the band saw

The first operation is cutting the bar stock to a 12 1/4" length on the band saw.

This is about as exciting as watching paint dry. This is a typical 4 X 6 bandsaw, made in China, sold by Harbor Freight. A cheap product, basically a kit from which the buyer can build a decent band saw. Takes lots of modification to make this into a workable tool. Mine isn't finished yet. Long way to go.
fish plate setup 1 fish plate setup 3

Vise setup for holding bar stock during rounding over operations


The next operation is standing the bar stock on edge in a pair of softjaws in the vise. The jaws are 13" long, to accommodate a 12 1/4" length of bar stock. The mill makes one pass with a round-over bit, the material is reversed, and the mill makes a second pass with the same bit. The stock will be cut into three 4" lengths, before drilling the holes. That operation is as boring as the first cut, so we won't ask you to watch the second cutting steps.

Rounding off the corners of the bar stock

Drilling the Rail Joiners


The last step is drilling the joiners, then deburring them. The deburr step is not shown.

Hover over, then click on, the lower right corner of any video to enlarge it to full screen