VI. FINAL ASSEMBLY
A. Solder electrical connections to power taps using 60/40 lead-tin solder and paste flux. Extra care must be taken that the power tap does not get too hot and melt the solder joint at the rail.
B. Install timing sensors per the manufacturer's instructions.
C. If the packing is not flush with the track's surface, use a sharp X-Acto knife to pick the packing out of the rail slot at some point and lift it out as necessary. Make sure no dried epoxy remains along either the rail or the slot's inner wall. Also, make sure that the existing packing has clean cut ends. Repeat original installation process, butting the replacement packing flush against the original packing.
D. Rail height is based on the average of its total useful life (say 10 years or more). As a new track, you should expect only slight wear over time. Once rail is set too low it is very difficult to raise it back up! Since the stock ride height for commercially available "H.O." type slot cars is .040", a target rail height of .015" is provided with the Railsetter.
If the rail is too low, use a sharp X-Acto knife to pick the packing out of the rail slot near the low rail and lift it out as necessary. Be extremely careful digging out all dried epoxy so as not to damage the track surface. Finally, run the knife along the track rail's back side to break it loose. Once the epoxy's bond is broken, using the Railsetter turned upside down should lift the rail for resetting. Follow the above guidelines for repairing packing. Repairs otherwise follow the original installation process.
If rail the rail height is too high, use a feeler gauge as a guide and run down each lane's rails length-wise with a diamond whetstone. Verify the desired final height by taking frequent measurements with dial calipers.
Even though the soft tempered rail is specifically designed to facilitate finishing, all necessary care must be taken when grinding the rails to their final height. Maintain consistent pressure with a steady hand to not only avoid over grinding but damage to the racing surface as well.
Diamond whetstones are available from Traver's Tool Co., Inc. at 1-800-221-0270 among other tool suppliers. Order #53-810-100 (fine) or #53-810-101 (coarse).
E. Acetone can be used with some success to remove dried epoxy from the track's surface, but only at the risk of damaging the packing.
F. Any incidental surface nicks or scratches that may occur during installation can often be removed using automotive rubbing compound mixed with penetrating oil. Be careful not to rub too hard or too deeply. The shine can often be restored using polishing compound for plastics and a buffing wheel.