Building track from scratch

Maybe small or thin angle iron from a Home

Depot or Lowes.

Folks used to hand lay track, and some probably still do, but I suspect they are buying rails and making their own ties. It could be a fun project.

I'm not sure this is one of those projects that if DIY'd would result in less expense. It is possible to build a jig to bend curves but if there is more than one radius in the plan it could get to be a lot of work to adjust, bend, check the radius, etc. Even before bending any rails, finding something with a suitable profile for train wheels is going to be a challenge, and you intend to use it outside so it's going to have to be a material that won't rust and corrode. I think you will also need jigs to hold the rails at the proper gauge when laying them down. It can be done.

How may feet do you need?  I have a lot of track  available.

Well, here's one guy's approach...FWIW:

...but maybe not the way I'd approach the task.  There are other DIY videos in a search that will be of help.

I wish you well on this endeavor...not only the initial production of the track, but the periodic maintenance thereof in the future...somewhat dependent upon your climate, seasonal changes, critters, insects, etc., etc..

Materials used...rail, ties, 'spikes', all need to consider the environment...even in a 'dead rail' application.  There are suppliers of brass, aluminum, stainless rail, but not on the cheap...IMHO.  Ties/sleepers?...rot-resistant...cedar, redwood, treated, non-wood.  Spikes?: Weather resistant/proof.  Etc., etc., etc..

Making through track can be the 'easiest' task...switches/turnouts will be another story.  Switch "kits" are available from a few suppliers, but, again, not on the cheap.

It would also be helpful to find someone who's already gone this route for outdoor trackage and pick their brains...and recommendations.  Hopefully locally, but maybe a forumite will volunteer assistance.

Viel Glück!

KD

@turkey_hollow_rr posted:

Folks used to hand lay track, and some probably still do, but I suspect they are buying rails and making their own ties. It could be a fun project.

They still do and all the supplies are readily available.  It can be fun project that can also be cost effective. But it's not an exercise for everybody.  Those afflicted with a need for instant gratification w/o possession of patience are better suited to pre-fab track out of a box.

Jeffrey,

  As @turkey_hollow_rr mentioned once you factor in all the parts needed, you might not actually be saving anything. The time involved can also cut into how long it takes to get trains rolling...and none of us are getting any younger!

  Good luck on your project and thank you for your service.

Tom

As a follow-up to my own post, I've used pairs of L-brackets (Home Depot or Lowes) to make straight track -- works very well. It's the curves that I'm not able to fabricate.

Jeff

Jeff,

What gauge/scale?

Mike

@Jeffrey H. posted:

As a follow-up to my own post, I've used pairs of L-brackets (Home Depot or Lowes) to make straight track -- works very well. It's the curves that I'm not able to fabricate.

Jeff

Have you looked at the wheels of your train to be sure the L-brackets aren't creating usual wear patterns?

To Tom Tee and Mellow Hudson Mike:

My intended backyard layout is a 40 foot straight run along a wall with a reverse loop at each end. If you have spare track please let me know! (The ideal gauge would be G, but either O or HO will be fine.)

Jeff