Would Oversized Rollers Work??

I think many people modify the switch to allow the deeper flanges instead of the loco.  What you are suggesting may be possible but I would consider modifying the track first.  Would also check very carefully to see f a larger roller would contact the axle or anything else by chance first. The second reason for working on the track instead of the engine would be that if it is jumping, you could get some derailments due to the jumping and likely you don't want your original Blue Comet landing on its side and getting scratched up.

I will have a similar problem with my modern Lionel 213 lift bridge.  It has tie spikes that sit high enough to upset older wheels with bid flanges so my solution will be to remove or reduce those spike heads.

Another option would be Gunrunnerjohn's method of a third pickup roller to the motor. Attach a wire to the e-unit and run it from the loco to the tender, attaching it to the tender's pickup roller. I did this with my prewar Blue Comet and no more e-unit issues rolling through the switches. 

John 

Jim,

   If your buddy will make the over sized rollers give it a try, and see what happens I for one would really like to know.  you can always switch back to the original rollers if needed.  Further if it does not work then adding and additional pickup is the way to go, to eliminate all the problems.

PCRR/Dave

There are other issues as well-like roller dropping into the gap, flanges catching parts of the frog, or closure rail or the guide rail... Dennis has it ... a careful filing down of the flange way to allow the roller to maintain contact is really all that is needed.... it wont take much.

Gentlemen,

What Rob advises works a great deal of the time, however each Tin Plate Engine is a little different, add the variables of 12 Wheel Tenders and Deep Flanged Wheels, along with the spacing of different pick ups, it makes reworking every  Switch & Track for all the different manufacturers O Gauge Engines & Rolling Stock almost impossible.  Some Tracks and Switches are just not compatible with Tin Plate Trains, it's just to much effort to make everything work correctly.  Now if you only have one Engine or even a couple Engines giving you problems, that is an entirely different matter.  I highly recommend choosing your track wisely when you want to run a lot of different Tin Plate Trains on a constant basis.

PCRR/Dave