back in the 70s, I handlaid all my track in code 40. Turnouts were made from pcboard cut into ties, and rail. Had to use solder to make the frogs and to attach the rails to the pc ties. For non turnout track I used rail Pliobonded (glued) to RailCraft wood ties. The gluing process involved heating the glue.
Yep, did the heated Pliobond trick too, back in the 80s. Worked sorta OK, but let loose once in a while. Had the most problems with grade changes and sharp curves; the rails had to be very carefully pre-shaped to exacty match the track geometry before bonding in place.
has anyone tried not linking rail segments with connectors - just solder? and what's the preference for maintaining insulation between blocks? just epoxy/other, or nonconductive inserts, or nothing?
For handlaid track, no rail joiners are used. Use two adjacent PC ties wherever rails meet. Just leave a tiny gap for insulated joints. (Actually, I leave a tiny gap between all long lengths of rail that meet to allow for expansion.)