Figure 2
Fitted Dowel with 3/8” diameter spigot, and mating dowel (not fitted), with 3/8” locating hole
Aligning Boards using Locating Dowels
Locating dowels between a pair of boards (or modules) givess excellent alignment, and helps to protect the exposed track ends, by properly aligning the boards whilst they are being joined together.
The locating dowels, shown in Figure 2 above, have a one-inch diameter flange, with a 3/8in. diameter spigot. The official name for these dowels is 'Pattern Makers Dowels'. Whilst they are generally supplied in bulk to the ‘trade’ from foundry suppliers, Ennis Hobbys can usually supply them in smaller quantities.
Assembly requires the two boards to be clamped together, and drill a 3/8-inch diameter hole through both end cross-pieces. Part the two boards. A modified drill-bit is used to cut the 1 inch diameter recess for the flange; this drill-bit has a 3/8 inch locating bar, or drill-bit, in front of the 1 inch diameter cutter. A recess of 5/16 inch is required for the flange, and this depth can be cut accurately if the drill can be fitted with a guide peg.
An alternative method requires the drilling of a small 3mm. diameter pilot hole through both end-pieces, and uses this hole to accurately centre the 1 inch diameter cutter (for electric drill), or twist bit (for drill brace). The latter may tear the wood at the edges and does not leave a flat recess; a sharp knife is required to finish the recess square - see Figure 1 above. A 3/8 inch diameter hole can then be drilled through one of the end-pieces, using the fiited female dowel for accurate positioning.
The dowel flange is fixed into the recess in the end cross-piece, and secured with three small screws. A smear of epoxy resin applied when finally fitting the dowel flanges adds to the long-term durability.
Method to avoid Damaging Track in Storage
An additional thickness of 9mm ply at the join with part on each board (see Figure 3) will ensure that the board structure extends 4mm beyond the end of the track and protects the track against damage when the board is rested on end (see drawing). In this case the detail dimensions of the board components must be adjusted to maintain the overall required length.
