Train Track Cutting

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77B36 INSTRUCTIONS for Train Track Bits #126372 & #126373 Revised 04/28/97 Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp. 1 Notes Before You Begin Woodcraft's carbide tipped Train Track Bits cut the male and female connections for a child’s wooden train track. The bits are designed for use only in a router table - do not attempt to use them in a free
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  Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-168611111 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp. 77B36 INSTRUCTIONS  for Train Track Bits #126372 & #126373 Revised04/28/97  Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-168622222 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp. Before You Begin Notes Woodcraft's carbide tipped Train Track Bits cut the male and female connections for a child’s wooden train track. The bits aredesigned for use only in a router table - do not attempt to use them in a freehand application. A thorough knowledge of router table use is necessary to use these bits. These instructions have been written to provide you with a better understanding of setup and cutting procedures. If it is your intent to duplicate existing track that you might already have, we recommend thatyou ignore the measurements given in these instructions and take new measurements directly from your track. Please thoroughly read these instructions before starting any cutting operations.Remember that the joints you cut are for a child’s toy and not a piece of furniture. Joints should be cleanly cut but the fit is notcritical. In fact, the connection between the male and female cuts should be fairly loose so that the child does not havedifficulty assembling and disassembling the track.Please adhere to all safety procedures while using these and any other router bits. Read all tool manuals before any cutting operations are attempted. Always wear proper safety equipment including safety glasses. 1   Right Angle Fixture 1 A right angle jig or fixture, in conjunction with the router table fence, is required tomachine the track. There are several commercial jigs and fixtures on the market thatyou can use, we made ours from scrap plywood. Whether store bought or shop built, the fixture should be able to hold a piece securely in a vertical position. Photo 1. Photo 1Photo 1Photo 1Photo 1Photo 1 1   2 Making Straight Track  Straight TrackStraight TrackStraight TrackStraight TrackStraight Track Straight track is not limited to any one length, although you should keep the length within a reasonable dimension somachining the part is not difficult. Common lengths for store bought track (excluding the male connector) are 4 1  / 4 , 5 3  / 4 and8 1  / 2 . Determine the length of your track while keeping in mind that the overall length of the piece with the male connection islonger than the dimension of the track. An 8 1  / 2 piece of track is actually 9 3  / 16 when you add in the length of the maleconnector.Because it is difficult to repeat exact router table setups time after time, wesuggest that you machine several pieces at a time to take advantage of eachsetup. Straight Track Blank DimensionsStraight Track Blank DimensionsStraight Track Blank DimensionsStraight Track Blank DimensionsStraight Track Blank Dimensions The Blank for a straight piece of track should be  7  / 16 thick, 1 9  / 16 wide and thelength of your choice. Drawing 1 .Drawing 1Drawing 1Drawing 1Drawing 1Drawing 1  Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-168633333 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp. Routing Female ConnectorsRouting Female ConnectorsRouting Female ConnectorsRouting Female ConnectorsRouting Female Connectors NOTE: We highly recommend pre-cutting most of the material around theNOTE: We highly recommend pre-cutting most of the material around theNOTE: We highly recommend pre-cutting most of the material around theNOTE: We highly recommend pre-cutting most of the material around theNOTE: We highly recommend pre-cutting most of the material around the joints so that your router bits can work more effectively. joints so that your router bits can work more effectively. joints so that your router bits can work more effectively. joints so that your router bits can work more effectively. joints so that your router bits can work more effectively. Drawing 2, Photo 2.Drawing 2, Photo 2.Drawing 2, Photo 2.Drawing 2, Photo 2.Drawing 2, Photo 2. Place the Ball End Bit into the router in your router table and set the height of thebit at 3  / 4 . The distance from thefence to the center of the bitshould be 25  / 32 . Drawing 3. Remember to pre-cut a smallopening at one end of the blank to take some pressure off of the bitand ensure a cleaner cut. Drawing 2. With the right angle jig against the fence, position the blank 90° to the table, flush to the fence and right angle fixture and secure with a clamp.With the right angle fixture firmly up against the fence, move the jig through therouter bit at a steady pace and make the cut. Make one pass and do not bring theblank back over the cutter. This will result in a double cut and possibly a kickbacksituation. Machine all straight blanks with this setup. This cut will be used as areference for the male cut. Photo 3. NOTE: If chip out occurs on the back side of theNOTE: If chip out occurs on the back side of theNOTE: If chip out occurs on the back side of theNOTE: If chip out occurs on the back side of theNOTE: If chip out occurs on the back side of the track blank, place a piece of stock behind the track blank, place a piece of stock behind the track blank, place a piece of stock behind the track blank, place a piece of stock behind the track blank, place a piece of stock behind theblank. This backer board will support the stockblank. This backer board will support the stockblank. This backer board will support the stockblank. This backer board will support the stockblank. This backer board will support the stockand the chip out will occur on it and not on theand the chip out will occur on it and not on theand the chip out will occur on it and not on theand the chip out will occur on it and not on theand the chip out will occur on it and not on the track blank. track blank. track blank. track blank. track blank. Routing Male ConnectorsRouting Male ConnectorsRouting Male ConnectorsRouting Male ConnectorsRouting Male Connectors Pre-cut the opposite end of the track blanks. Drawing 2, Photo 2. Place the MaleConnector Bit into the router in your router table and set the height of the bit atapproximately 11  / 16 . The distance from the fence to the upper outside edge of thebit should be approximately 5  / 8 . Drawing 4. With the right angle jig against thefence, position the end of the blank 90° to the table, flush to the fence and the right angle fixtureand secure with a clamp. Move the jig through therouter bit at a steady pace and make the cut. Flip the stock and repeat the cutting process (this willensure that the cut is exactly centered on theblank). Photo 4 . Fine adjustment can be made to this cut by moving the fence in or out from the bit.Check the fit of the male/female connections at this time. Remember that the fit should be loose enough that a child has no difficulty putting together or taking apart the wooden pieces. Make any adjustments needed for a better fit and then machine all straight blanks with this setup. Train Track GroovesTrain Track GroovesTrain Track GroovesTrain Track GroovesTrain Track Grooves The train track grooves are approximately 1  / 4 wide, 1  / 8 deep and 1 on center. The train track groovesare made with a 1  / 4 straight router bit. Bit height is 1  / 8 and the distance from the center of the bit to the fence is 5  / 16 . Drawing 5 . Using a push blockhold the track blank firmly to the table and upagainst the fence. Photo 5 . Move the blank over thebit with a steady pace. Flip the stock and repeat theprocess along the other edge.Photo 2Photo 2Photo 2Photo 2Photo 2Drawing 2Drawing 2Drawing 2Drawing 2Drawing 2Photo 3Photo 3Photo 3Photo 3Photo 3Drawing 3Drawing 3Drawing 3Drawing 3Drawing 3Drawing 4Drawing 4Drawing 4Drawing 4Drawing 4Photo 4Photo 4Photo 4Photo 4Photo 4Drawing 5Drawing 5Drawing 5Drawing 5Drawing 5Photo 5Photo 5Photo 5Photo 5Photo 5  Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-1686Woodcraft, 210 Wood County Industrial Park, P.O. Box 1686, Parkersburg, WV 26102-168644444 © 1999 Woodcraft Supply Corp. “Helping You Make Wood Work” is a trademark of Woodcraft Supply Corp. Drawing 6Drawing 6Drawing 6Drawing 6Drawing 6It is important to ease the interior edges of the groovesso that there are no sharp corners exposed where thewheels might have a tendency to jump the track. Edgescan be eased by sanding the grooves in the track byhand. Outside edgesof the train trackcan be eased withsandpaper or byusing a chamfering bit. The chamfershould be veryslight, only a 1  / 16 ,  just enough to soften the edge.Drawing 6, Photo 6 .Completed trackinterlocked. Photo 7  . Completed track can be left natural or finished with a child safe, nontoxic finish.Photo 6Photo 6Photo 6Photo 6Photo 6Photo 7Photo 7Photo 7Photo 7Photo 7Making the curved track requires a circle cutting jig that will hold a pre-cut blank of wood and a right angle jig to hold a curved piece of woodrather than a straight one. The completed curved track is 1  / 8  th of a circlewith track grooves on both sides. Making curved track requires cutting  track grooves that are partial arcs of two concentric circles. To make these cuts you will use two different centers on your router table.Make a circle template from a piece of scrap plywood about 11 x 13 .Draw a center line lengthwise along the jig. Drill a 3  / 16 pivot hole, on thecenter line, about 2 from one edge. Mark a 90° guide line on the template 6 11  / 16 from the center of the pivot hole. This will mark theposition of the wood blank on the template. Drawing 7. Cut severalwood blanks  7  / 16 thick, 3 wide and 8 in length. Place a blank on the jig at the 90° guide line and glue support blocks around itsperimeter. Photo 8 . Glue a support block that is the same thicknessas the track blank near the pivot hole, this will support the jig so that it willstay level with the table. Drill holes for the “centers” of the arcs into yourrouter table. The center of the firsthole should be 8 1  / 4 from the center of  the bit. The center of the second holeshould be 1 farther from the bit then the center of the first hole. See photo9. If you can't drill directly into your table, clamp a false table top of  3  / 4 plywood over your table. Drill aclearance hole for the router bit, thendrill your center holes into the false table. The position of these centersneeds to be as accurate as possible.TIP: We used aTIP: We used aTIP: We used aTIP: We used aTIP: We used a 33333  / / / / / 1616161616 bit to drill our center holes and then used that same drill bit as the pivot point for our jig. bit to drill our center holes and then used that same drill bit as the pivot point for our jig. bit to drill our center holes and then used that same drill bit as the pivot point for our jig. bit to drill our center holes and then used that same drill bit as the pivot point for our jig. bit to drill our center holes and then used that same drill bit as the pivot point for our jig.BlankBlankBlankBlankBlankPivot HolePivot HolePivot HolePivot HolePivot HoleCenterCenterCenterCenterCenterHolesHolesHolesHolesHolesDrawing 7Drawing 7Drawing 7Drawing 7Drawing 7Photo 9Photo 9Photo 9Photo 9Photo 9Photo 8Photo 8Photo 8Photo 8Photo 8 1   Making Curved Track  3
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