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The pickup rollers on my Williams and Lionel engines that I run non stop at train shows are wearing rather fast on tubular track. They seem to wear less on track that has a flat top center rail. There has been arching on some trains and it burns the surface where it touches the rail and loose contact. They are not as much dirty as burnt and worn. The trains run down the track sparking and eventually stall out, tripping the reverse unit in some. I have added a trailing car with electrical pickup to the Lion Chief engines that helps or 2nd diesel or car with pickup rollers wired to the Williams engines.

Would sanding or dremel sanding damage or buff up the surface enough that I could restore the electrical contact? I keep the tracks very clean. Replacement is an option but expensive and time consuming. 

Last edited by kj356
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The smoother the polishing the better.

Spring tension is important too. Pressure has a huge impact on continuty. More pressure =less resistance to overcome.

The rounded head of tubular will wear faster because the load is on less Sq.inches, but the end result is more contact area (at times anyhow). Also under severe wear, the round rail head will let a roller track smoothly having no edges to ride up on or wedge on (on old super O's thin center rail and pickup shoes this is kinda easy to do. Rollers take much longer to wear grooves that bad)

I had a postwar 623 NW-2 whose rollers and pins, were badly oxidized from arcing, which caused more oxidation, which caused more arcing, until it got to where the collector assembly was too hot to touch after only a minute or two of running. I finally tried TV tuner cleaner on it, with lots of cotton swabs, and that fixed it right up.

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