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All of that is a lot of work, and so I nstead of reinventing the wheel I was curious if there was a finer standard…… which leads me back to the question.
Kinda. There is an NMRA standard for Fine:N, but that's all there is. There are no gauges available for that, so you're kinda on your own. Looking at the numbers, I think all the Fine:N is within the Standard:N specs, it just has tighter tolerances. https://www.nmra.org/sites/default/files/standards/sandrp/pdf/S-3.1%202006.01.pdf
I'm wondering if it would help if you tightened up the tolerances of the flange way width and made them narrower than the standard. I know a #10 frog has to be very skinny and very sharp. When I build my turnouts (mostly #6 and #8), I always struggle with how far in to put the frog rails to minimize that gap (I have FT fixtures). I did build a curved crossover that I think has a #10 frog. I've found that the point of the frog has to basically intersect with where the closure rail would be if it continued through the frog, if that makes sense.Below is the curved crossover I built a few years ago with the #10 frog. I use FVM wheelsets, and I believe they are the narrow tread. I don't have any problems with any of my equipment going through either frog.https://www.therailwire.net/forum/index.php?action=gallery;sa=view;id=37438
I fill the frog area with solder and then use one of my old (not any of my good ones) NMRA gauges and scrape the solder out till the depth is correct