First off...I highly recommend using rail joiners for their mechanical proclivities, not for conducting electrical current or DCC signal packets. This is why I solder a 22AWG solid copper 6 to 8 inch feeder wire near the middle of each and every piece of powered rail on my layout. This has served me well over the past 9 years on my portable layout as I have experienced zero electrical problems with no dead rail anywhere, anytime.
Secondly, I solder each and every rail joiner using 96/4 Tin/Silver silver-bearing solder, which is 5 to 6 times stronger than common electronics solder and melts at only a few degrees higher. Of course, I use the very best flux ever made for models and track fabrication...Superior Supersafe No. 30 Soldering Flux Gel and Paste...both solder and flux available here:
https://www.hnflux.com/page22.html One thing that has always bothered me about rail joiners is that normal ties don't work under them. This leaves no spikeheads every place there's a joiner, and ties that are lower than the rest, or have visible gaps instead of spikeheads..and I want the smoothest, distraction-free track I can get, with spikeheads everywhere except at my PCB turnouts.
So, since silver-bearing solder is so strong, I decided the way to mostly get rid of the big-ol' track joiner problem, would be to make them smaller...so they're not "big" any more, and combined with strong silver-bearing solder, should provide just as strong a joint as full-sized joiners without any solder, and/or full-sized joiners soldered with regular electronics solder.
Also, I don't want ties without spikeheads or having visible gaps on either side of the rail joiners. I want to sight down my track and not see lower ties everywhere there's a joiner, nor do I want to see no spikehead on the rail foot everywhere there's a joiner.
I decided to cut my normal-sized joiners to the length of the space between ties...very short...and see how that worked mechanically after soldering with silver-bearing solder.
Additionally, I would cut the spacers between ties away for three or four ties, then slide the ties back from where the joiner would be soldered, solder two pieces of track together using the short joiners, then slide the ties back in place, with the short joiners soldered between two of them.
Photo (1) - Ties with spacers cut away, and slid back from where the short joiners will be soldered:Photo (2) - Track joined using shortened rail joiners soldered, and with ties slid back in place - before final tie spacing is finished:Photo (3) - Joined track after first coat of Krylon Camo Ultra Flat Black paint:As you can see, they're hard to find once painted. Even harder after some weathering and ballasting.
Photo (4) - Here's an overall view of the West End of Echo with one set of shortened rail joiners visible in this view. See if you can find 'em or see any odd-looking low ties that normally would be slipped under regular-length rail joiners:The most difficult thing about using shortened rail joiners is cutting them to length. The secret is to first, cut away the "tongues" on either end of normal rail joiners, then mount the rail joiner to a scrap piece of Code 55 rail. Then, cut both rail joiner and rail at the same time using sharp flush cutters. On the first cut this will produce a flush cut on one side and a smashed cut on the other. I take a fine paper sanding disk in my Dremel and lightly sand the nice, flush-cut joiner that is still mounted to the rail I've just cut...this gets rid of any external burrs. Then, I slide the shortened rail joiner down the rail it's mounted on, away from the sanded cut I just made. This gets rid of any internal burrs, which you can sometimes see hanging on to the rail joiner. I then make a cut on the rail joiner that's got the smashed end, cutting the mounted rail joiner to length and discarding the part of the joiner I've just cut off that has two smashed cuts. I hit the second joiner with my Dremel sanding disk, push it away from the sanded cut on the rail, and I've got two short rail joiners from one long joiner.
I then mount the joiners to one of the pieces of track I've already cut in the middle between two ties and sanded, then cut the spacers on 4 or 5 ties and moved them back away from the future soldered joint. I also dress the ends of the rails with a fine jeweler's file to get rid of any burrs and file a tiny 45 degree angle on the sharp corners of the rail foot..tiny angles.
I slip the mounted joiners back away from the end of the piece of flex I've just mounted them to, then place the piece of rail I've cut and prepared identically so that the rail ends are touching...making sure the rails are straight and there's no kink at the joint.
Then, I slide one of the joiners up to where the rails are touching, and center it on the cut...flux and solder...let cool, and check if the rails are even all the way around and there's no kink. After I'm happy, I do the same with the other rail.
I then curve the rail if I have to before sliding the ties back into place.
I also swab the joint with a Q-tip soaked in 91% IPA to clean off any burnt flux and facilitate the ties sliding on the rail foot easily.
I then slide the ties back into place, adjusting their spacing if it looks like I have to.
All of this takes a lot less time to do than to write about it...and after it's done, there's no coming back after the track is glued down and fiddling around with modifying extra loose ties, then inserting them under the full-length rail joiners, and gluing them in place.
Plus, you double the amount of rail joiners you have.
Sometimes I can get three small rail joiners out of one, but...usually I don't try anymore. I'm happy with two.
There's also a way to join flex without any joiners at all, but I haven't done that yet...and I'm happy with my shortened-joiner way of doing it both from a cosmetic and functional viewpoint.
Maybe this method will suit your track-laying wishes.
The only absolutely necessary things needed for this are 96/4 Silver-bearing solder, a hot, clean-tipped tinned iron, and sharp flush cutters. Oh, and Superior Supersafe No. 30 Soldering Flux Gel.
Cheerio!
Bob Gilmore