Atlas C55 turnout self-contained micro switch mount

[Lemosteam]

This is a proof of concept for the subject switch mount. I have been working on this for a little while for my layout.  My goal was to have a permanent mount for the frog control switch and fingertip control of the points.  Atop the switch post is a second version of the Keystone Details pneumatic switch machine.

The throw distance on the Radio Shack switch is perfect as pointed out by so many over the years. And the turnout operates well when I push or pull the switch and the points are held tight to the rails.

Sorry for the crappy broken turnout that I started with, I did not want to test on a brand new one.



The white nylon clip has four tabs on the corners that mount under the throwbar guides that I heat staked with a sharp point soldering tip, massaging the two materials together.  This will not work with FUD by the way, I have found that it does not melt, but the white flexible material does and will blend well with the Atlas tie material.



On the bottom are two flex tabs that catch the back side of the switch.  I will likely make them longer. For this test I glued the switch inside as the switch tends to work out of the clip under load. You could also melt them to the back of the switch, which also works.



The wire shape is mainly a guess, for the test. I may design a FUD bending jig for consistency. 



Here are the parts from Shapeways:



I just like the idea of a self contained setup that can just get mounted to the layout as a unit, wires and all. 

Thoughts, suggestions?
 

[Ed Kapuscinski]

I love it.

I mean get recommend adding a "leg" that runs under the head ties so there's more joining space.

[towl1996]

Brilliant!! Will the first version switch machines work with this?

[mmagliaro]

Hmmmm and ya know what?  For those of us who have already mounted little slide switches to all their turnouts
onto a layout, it still looks like the top piece could go over the switch handle, secured with some Walthers Goo
or epoxy,  and work.  Are those switch machines very specific to PRR or are they a common design?

What is the size of the slide switch handle that this is designed to fit over?

[Lemosteam]

@towl1996 no the other design will not, it was designed for a 3mm post. But I have a similar mount for that, it's just huge. 

Originally those were dual use, on a switch or on just mounted static to the layout.

Hi Max, this fits a 1.5mm switch post. These machines are all over the NEC.  I do not know if they are used out west. 

[narrowminded]

Looks like a good idea.   Could that switch mount be made in ABS?  I ask because the tie material, at least on code 80, is solvent weldable with standard model glue (MEK) as is ABS.  ABS makes good mechanical parts and a solvent welded joint in compatible materials would be strong, durable, and it's easy to making a neat joint.

[Lemosteam]

Realize that mess is from three separate attempts on the same switch, all similar results, just tested to fail.  I will try this on a brand new switch this weekend, I need to do this for a bunch of switches for my layout.

I am not a materials expert, but if Shapeways has a printable version of ABS maybe you could point it out from their materials listings. www.shapeways.com

@towl1996 pm me please.

[Cajonpassfan]

John, I'm loving the concept, but not loving the throw bar arrangement...
Here's a thought: I wonder whether an appropriately sized wire with a vertical "double L" rather than a horizontal zigzag, would be cleaner. Drill switch handle along lateral axis, bend down 90 degrees to just clear the deck, bend again to continue toward runout throwbar, insert the turnout end from below the plastic throw bar (with just a short upbend)? A simple bending jig should yield consistent results, the center bend provide a bit of "flex"?
A theory, anyways...
Otto K.

[narrowminded]

https://www.shapeways.com/blog/archives/338-grey-is-good-grey-robust-fdm-abs-plastic.html

As I was linking to this I discovered that they no longer offer this material.  I wonder if a search could find another supplier?  I think ABS is a fairly common printer material.

[Lemosteam]

John, I'm loving the concept, but not loving the throw bar arrangement...
Here's a thought: I wonder whether an appropriately sized wire with a vertical "double L" rather than a horizontal zigzag, would be cleaner. Drill switch handle along lateral axis, bend down 90 degrees to just clear the deck, bend again to continue toward runout throwbar, insert the turnout end from below the plastic throw bar (with just a short upbend)? A simple bending jig should yield consistent results, the center bend provide a bit of "flex"?
A theory, anyways...
Otto K.

Could you draw a picture of what you mean?  I'm hesitant to put the wire under the throwbar in case the wire pops out.  At least from above it could be replaced.  As I said, that was hastily done on the fly.  I suppose a drop of solder on the end could prevent the wire fron coming out...

[Wolf N Works]

Following this with great interest.

[Iain]

A lulzbot will do ABS

[Lemosteam]

Some Materials Engineer friends have indicated that there are existing adhesives the will bond both materials.  Will share after testing!  I am going to change the design a little to obtain more surface contact area for gluing the clip to the turnout, and create a wire bending jig for the wire.

I think I understand what @Cajonpassfan  is looking for in the wire.  One plus of the wire is it serves as the connection for the switch machine to the switch post any way you bend the wire- so no glue there!

[Cajonpassfan]

John, I'm not sure my "vertical bend" idea would work. In order for the bend to provide enough flex or "springiness" there would need to be enough distance between the top and bottom bends. Your horizontal zig zag does that better. Out of curiosity, what is the vertical dimension between bottom of the ties and a point where handle would be drilled to accept actuating wire?
Otto K.

[Lemosteam]

The clip is designed to be flush with the top of the throwbar guides, so the hole I drilled is tangent to that surface.