This is a tale of great expectations gone awry. Whether it is due to my own
incompetence, materials used or available to me, or a fundamental material
composition flaw, I will leave to the reader. My point to this sorry tale is to provide a warning to fully
investigate and satisfy yourself that all steps necessary to use a product are
satisfactory prior to quantity purchase.
My original trackwork plan for the HO scale SP Cascade Line
was to use Fast Tracks turnouts throughout. As I approached full-size planning a year ago, I purchased
sample Micro Engineering # 6 and Walthers Shinohara #8 turnouts to assist with
planning. Recalling the NMRA
conformance testing of HO scale turnouts a couple of years ago, I knew the ME
turnout was pretty close to standard, though a minor flaw prevented an NMRA
conformance warrant. I was
sufficiently impressed by the mechanical design of the ME turnout, that I
altered my plan to use the ME turnouts where #6 size were needed, but still
using Fast Tracks #8 turnouts for the longer (mostly mainline) locations.
Preparatory to final installation of track in Springfield, I
have been attempting to solder frog wires to the underside of the ME frog
casting. ME provides a “button” on
the underside of the frog for this purpose. The idea is to solder a wire onto this underside button and
then feed it through a hole in the roadbed for the electrical connections
needed for a “hot” frog (frog polarity switches with point movement).
Frog button on underside of Micro Engineering turnout.
I have had extreme difficulty making that frog wire solder
joint. The frog casting metallurgy
reacts quite differently than nickel silver rail. It is very hard (difficult to drill into) and does not take
solder easily. I have tried
several methods for attaching the frog wires. Each begins with a very clean button. I have used both a fiberglass brush and
a brass wire brush to clean the button.
My 35 watt electronics soldering iron could not achieve a solder joint
at all. I have used a resistance
soldering unit to apply very localized high heat. I have used both the soldering unit tweezers and the
alternative ground clip and probe.
I have tried various unit settings, including very high.
For solder joint geometry, I have tried direct soldering wherein
I flatten the frog wire by crimping, bend the wire to a 90 degree angle, and
hold it on the frog button. Both
button and wire have rosin flux applied. Using the solder unit ground clip on the top of the
frog, I apply heat with the probe to both button and wire. Initial attempts achieved only cold
solder joints, easily broken.
Raising the heat level simply led to melted—and often burning (!)
ties! Clearly, I was using
too much heat!
Melted ties near frog on Micro Engineering turnout.
I moved on to drilling a hole to feed the wire into,
reducing mechanical stresses, while providing more surface for the solder to
make a joint. This, too, resulted
in melting and burning ties.
I achieved a successful solder joint on only about half of my
first dozen attempts. I destroyed
three (and counting!) turnouts along the way to making a dozen “successful”
joints. This is absolutely
unacceptable.
I finally did make contact with Micro Engineering. They were unable to duplicate my
symptoms. They used a large
soldering iron so apparently had sufficient quick heat.
I finally developed a successful technique involving
drilling a hole, quickly getting the frog onto my vise to relieve any heat
build-up. I then add the
resistance solder unit ground clip on the top of the frog, resting the turnout
and clip assembly upside down spanning the jaws of my vise. Flux and the frog wire are inserted,
the probe positioned and then heat applied while feeding solder (standard
electrical 60/40 rosin core). The
addition of the vise seems to have largely relieved the heat buildups, while
the resistance solder unit is able to apply sufficient localized heat to
achieve a satisfactory solder joint.
Though I found a technique to keep from destroying still more turnouts,
I am not satisfied with the steps using tools and fixtures away from the layout
location.
I am shifting back to my original plan to use Fast Tracks
jig-built turnouts throughout. I
will attempt to salvage what I can of my current ME turnouts, but will buy no
more, indeed, cancelling a large order.
I am disappointed and frustrated. Railroad construction will grind to a halt until the Fast
Tracks jigs and fixtures arrive.
Caveat Emptor!
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