Making Custom Radius Super O




Start by cutting through the webbing on the inside (outside for smaller radius):








Next, pry back the metal clips just enough to let the outer rail slide easily through all three tie plates.

(The inner one for tighter radii). A sharp tip on the screwdriver is needed to get between the rail and clips.






Next, draw an arc on paper equal to the radius you want, plus ¼" for the ties.






Then, place the track so the center and one end tie plate rest on a bench top.

Hit with a rubber hammer until the radius matches the curve on the paper.

Repeat on other half of track.







Look up the amount to cut on the table below if bending curve track; use the next table below this one for bending straights:

Note that the blue highlighted diameters use only full sections

BENDING SUPER - O CURVES



Diameter outer rail (Inches) Cut Off Center rail (Inches) Cut Off Inner rail (Inches) 90 Degree Full Sections (#) 90 Degree Cut Section Length (Inches) Cut Off Center rail (64ths) Cut Off Inner rail (64ths) 90 Degree Cut Section Length (Inch/64ths)
24 0.090 0.180 2 0.000 6 12 0  
25 0.079 0.158 2 0.755 5 10   48/64
26 0.069 0.138 2 1.511 4 9 1 33/64
27 0.060 0.120 2 2.266 4 8 2 17/64
28 0.051 0.103 2 3.022 3 7 3 1/64
29 0.043 0.087 2 3.777 3 6 3 50/64
30 0.036 0.072 2 4.532 2 5 4 34/64
31 0.029 0.058 2 5.288 2 4 5 18/64
32 0.022 0.045 2 6.043 1 3 6 3/64
33 0.016 0.033 2 6.799 1 2 6 51/64
34 0.011 0.021 2 7.554 1 1 7 35/64
35 0.005 0.010 2 8.309 0 1 8 20/64
36 0 Cut Off Outer (Inches) 3 0.000 0 0 0  
37 0.005 0.010 3 0.785 0 1   50/64
38 0.010 0.020 3 1.571 1 1 1 37/64
39 0.014 0.029 3 2.356 1 2 2 23/64
40 0.019 0.037 3 3.142 1 2 3 9/64
41 0.023 0.045 3 3.927 1 3 3 59/64
42 0.027 0.053 3 4.712 2 3 4 46/64
43 0.030 0.061 3 5.498 2 4 5 32/64
44 0.034 0.068 3 6.283 2 4 6 18/64
45 0.037 0.074 3 7.069 2 5 7 4/64
46 0.040 0.081 3 7.854 3 5 7 55/64
47 0.043 0.087 3 8.639 3 6 8 41/64
47.55 0.045 0.090 4 0.007 3 6 0  
48 0.046 0.093 4 0.360 3 6   23/64
49 0.049 0.098 4 1.145 3 6 1 9/64
50 0.052 0.104 4 1.931 3 7 1 60/64
51 0.054 0.109 4 2.716 3 7 2 46/64
52 0.057 0.114 4 3.502 4 7 3 32/64
53 0.059 0.119 4 4.287 4 8 4 18/64
54 0.062 0.123 4 5.072 4 8 5 5/64
55 0.064 0.128 4 5.858 4 8 5 55/64
56 0.066 0.132 4 6.643 4 8 6 41/64
57 0.068 0.136 4 7.429 4 9 7 27/64
58 0.070 0.140 4 8.214 4 9 8 14/64
59 0.072 0.144 4 9.000 5 9 9  
59.09 0.072 0.144 5 0.005 5 9 0  
60 0.074 0.147 5 0.720 5 9   46/64
61 0.075 0.151 5 1.505 5 10 1 32/64
62 0.077 0.154 5 2.291 5 10 2 19/64
63 0.079 0.158 5 3.076 5 10 3 5/64
64 0.080 0.161 5 3.862 5 10 3 55/64
65 0.082 0.164 5 4.647 5 11 4 41/64
66 0.084 0.167 5 5.432 5 11 5 28/64
67 0.085 0.170 5 6.218 5 11 6 14/64
68 0.086 0.173 5 7.003 6 11 7  
69 0.088 0.176 5 7.790 6 11 7 51/64
70 0.089 0.178 5 8.574 6 11 8 37/64
70.63 0.090 0.180 6 0.004 6 12 0  
71 0.090 0.181 6 0.295 6 12   19/64
72 0.092 0.183 6 1.080 6 12 1 5/64
73 0.093 0.186 6 1.865 6 12 1 55/64
74 0.094 0.188 6 2.651 6 12 2 42/64
75 0.095 0.191 6 3.436 6 12 3 28/64
76 0.096 0.193 6 4.222 6 12 4 14/64
77 0.098 0.195 6 5.007 6 12 5  
78 0.099 0.197 6 5.792 6 13 5 51/64
79 0.100 0.199 6 6.578 6 13 6 37/64
80 0.101 0.201 6 7.363 6 13 7 23/64
81 0.102 0.203 6 8.149 7 13 8 10/64
82 0.103 0.205 6 8.934 7 13 8 60/64
82.17 0.103 0.206 7 0.003 7 13 0  
83 0.104 0.207 7 0.655 7 13   42/64
84 0.105 0.209 7 1.440 7 13 1 28/64
85 0.105 0.211 7 2.225 7 13 2 14/64
86 0.106 0.213 7 3.011 7 14 3 1/64
87 0.107 0.214 7 3.796 7 14 3 51/64
88 0.108 0.216 7 4.582 7 14 4 37/64
89 0.109 0.218 7 5.367 7 14 5 23/64
90 0.110 0.219 7 6.152 7 14 6 10/64
91 0.110 0.221 7 6.938 7 14 6 60/64
92 0.111 0.222 7 7.723 7 14 7 46/64
93 0.112 0.224 7 8.509 7 14 8 33/64
93.71 0.112 0.225 8 0.001 7 14 0  
94 0.113 0.225 8 0.229 7 14   15/64
95 0.113 0.227 8 1.015 7 15 1 1/64
96 0.114 0.228 8 1.800 7 15 1 51/64
97 0.115 0.230 8 2.585 7 15 2 37/64
98 0.115 0.231 8 3.371 7 15 3 24/64
99 0.116 0.232 8 4.156 7 15 4 10/64
100 0.117 0.234 8 4.942 7 15 4 60/64
101 0.117 0.235 8 5.727 8 15 5 47/64
102 0.118 0.236 8 6.512 8 15 6 33/64
103 0.119 0.237 8 7.298 8 15 7 19/64
104 0.119 0.239 8 8.083 8 15 8 5/64
105 0.120 0.240 8 8.869 8 15 8 56/64
105.25 0.120 0.240 9 0.000 8 15 0  
106 0.120 0.241 9 0.589 8 15   38/64
107 0.121 0.242 9 1.375 8 15 1 24/64
108 0.122 0.243 9 2.160 8 16 2 10/64
109 0.122 0.244 9 2.945 8 16 2 60/64
110 0.123 0.245 9 3.731 8 16 3 47/64
111 0.123 0.246 9 4.516 8 16 4 33/64
112 0.124 0.247 9 5.302 8 16 5 19/64
113 0.124 0.248 9 6.087 8 16 6 6/64
114 0.125 0.249 9 6.872 8 16 6 56/64
115 0.125 0.250 9 7.658 8 16 7 42/64
116 0.126 0.251 9 8.443 8 16 8 28/64
117 0.126 0.252 10 0.164 8 16   10/64
118 0.127 0.253 10 0.949 8 16   61/64
119 0.127 0.254 10 1.734 8 16 1 47/64
120 0.127 0.255 10 2.520 8 16 2 33/64


BENDING SUPER - O STRAIGHTS



Diameter outer rail (Inches) Cut Off Center rail (Inches) Cut Off Outer rail (Inches) 90 Degree Full Sections (#) 90 Degree Cut Section Length (Inches) Cut Off Center rail (64ths) Cut Off Inner rail (64ths) 90 Degree Cut Section Length (Inch/64ths)
24 0.258 0.516 2 0.850 17 33   54/64
25 0.248 0.495 2 1.635 16 32 1 41/64
26 0.238 0.476 2 2.420 15 30 2 27/64
27 0.229 0.458 2 3.206 15 29 3 13/64
28 0.221 0.442 2 3.991 14 28 3 63/64
29 0.213 0.427 2 4.777 14 27 4 50/64
30 0.206 0.413 2 5.562 13 26 5 36/64
31 0.200 0.399 2 6.347 13 26 6 22/64
32 0.193 0.387 2 7.133 12 25 7 8/64
33 0.188 0.375 2 7.918 12 24 7 59/64
34 0.182 0.364 2 8.704 12 23 8 45/64
34.38 0.180 0.360 3 0.002 12 23 0  
35 0.177 0.354 3 0.489 11 23   31/64
36 0.172 0.344 3 1.274 11 22 1 11/64
37 0.167 0.334 3 2.060 11 21 2 4/64
38 0.163 0.326 3 2.845 10 21 2 54/64
39 0.159 0.317 3 3.631 10 20 3 40/64
40 0.155 0.309 3 4.416 10 20 4 27/64
41 0.151 0.302 3 5.201 10 19 5 13/64
42 0.147 0.295 3 5.987 9 19 5 63/64
43 0.144 0.288 3 6.772 9 18 6 49/64
44 0.141 0.281 3 7.558 9 18 7 36/64
45 0.137 0.275 3 8.343 9 18 8 22/64
45.84 0.135 0.270 4 0.003 9 17 0  
46 0.135 0.269 4 0.128 9 17   8/64
47 0.132 0.263 4 0.914 8 17   58/64
48 0.129 0.258 4 1.699 8 17 1 45/64
49 0.126 0.253 4 2.485 8 16 2 31/64
50 0.124 0.248 4 3.270 8 16 3 17/64
51 0.121 0.243 4 4.055 8 16 4 4/64
52 0.119 0.238 4 4.841 8 15 4 54/64
53 0.117 0.233 4 5.626 7 15 5 40/64
54 0.115 0.229 4 6.412 7 15 6 26/64
55 0.112 0.225 4 7.197 7 14 7 13/64
56 0.110 0.221 4 7.982 7 14 7 63/64
57 0.109 0.217 4 8.768 7 14 8 49/64
57.30 0.108 0.216 5 0.003 7 14 0  
58 0.107 0.213 5 0.553 7 14   35/64
59 0.105 0.210 5 1.339 7 13 1 22/64
60 0.103 0.206 5 2.124 7 13 2 8/64
61 0.101 0.203 5 2.909 6 13 2 58/64
62 0.100 0.200 5 3.695 6 13 3 44/64
63 0.098 0.196 5 4.480 6 13 4 31/64
64 0.097 0.193 5 5.265 6 12 5 17/64
65 0.095 0.190 5 6.051 6 12 6 3/64
66 0.094 0.188 5 6.836 6 12 6 54/64
67 0.092 0.185 5 7.622 6 12 7 40/64
68 0.091 0.182 5 8.407 6 12 8 26/64
68.76 0.090 0.180 6 0.004 6 12 0  
69 0.090 0.179 6 0.193 6 11   12/64
70 0.088 0.177 6 0.978 6 11   63/64
71 0.087 0.174 6 1.763 6 11 1 49/64
72 0.086 0.172 6 2.549 6 11 2 35/64
73 0.085 0.170 6 3.334 5 11 3 21/64
74 0.084 0.167 6 4.119 5 11 4 8/64
75 0.082 0.165 6 4.905 5 11 4 58/64
76 0.081 0.163 6 5.690 5 10 5 44/64
77 0.080 0.161 6 6.476 5 10 6 30/64
78 0.079 0.159 6 7.261 5 10 7 17/64
79 0.078 0.157 6 8.046 5 10 8 3/64
80 0.077 0.155 6 8.832 5 10 8 53/64
80.22 0.077 0.154 7 0.005 5 10 0  
81 0.076 0.153 7 0.617 5 10   40/64
82 0.075 0.151 7 1.403 5 10 1 26/64
83 0.075 0.149 7 2.188 5 10 2 12/64
84 0.074 0.147 7 2.973 5 9 2 62/64
85 0.073 0.146 7 3.759 5 9 3 49/64
86 0.072 0.144 7 4.544 5 9 4 35/64
87 0.071 0.142 7 5.330 5 9 5 21/64
88 0.070 0.141 7 6.115 5 9 6 7/64
89 0.070 0.139 7 6.900 4 9 6 58/64
90 0.069 0.137 7 7.686 4 9 7 44/64
91 0.068 0.136 7 8.471 4 9 8 30/64
91.68 0.067 0.135 8 0.005 4 9 0  
92 0.067 0.135 8 0.257 4 9   16/64
93 0.067 0.133 8 1.042 4 9 1 3/64
94 0.066 0.132 8 1.827 4 8 1 53/64
95 0.065 0.130 8 2.613 4 8 2 39/64
96 0.064 0.129 8 3.398 4 8 3 25/64
97 0.064 0.128 8 4.184 4 8 4 12/64
98 0.063 0.126 8 4.969 4 8 4 62/64
99 0.063 0.125 8 5.754 4 8 5 48/64
100 0.062 0.124 8 6.540 4 8 6 35/64
101 0.061 0.123 8 7.325 4 8 7 21/64
102 0.061 0.121 8 8.111 4 8 8 7/64
103 0.060 0.120 8 8.896 4 8 8 57/64
103.14 0.060 0.120 9 0.006 4 8 0  
104 0.059 0.119 9 0.681 4 8   44/64
105 0.059 0.118 9 1.467 4 8 1 30/64
106 0.058 0.117 9 2.252 4 7 2 16/64
107 0.058 0.116 9 3.038 4 7 3 2/64
108 0.057 0.115 9 3.823 4 7 3 53/64
109 0.057 0.114 9 4.608 4 7 4 39/64
110 0.056 0.112 9 5.394 4 7 5 25/64
111 0.056 0.111 9 6.179 4 7 6 11/64
112 0.055 0.110 9 6.965 4 7 6 62/64
113 0.055 0.110 9 7.750 4 7 7 48/64
114 0.054 0.109 9 8.535 3 7 8 34/64
114.60 0.054 0.108 10 0.007 3 7 0  
115 0.054 0.108 10 0.321 3 7   21/64
116 0.053 0.107 10 1.106 3 7 1 7/64
117 0.053 0.106 10 1.892 3 7 1 57/64
118 0.052 0.105 10 2.677 3 7 2 43/64
119 0.052 0.104 10 3.462 3 7 3 30/64
120 0.052 0.103 10 4.248 3 7 4 16/64





Measure the amount to cut off the outside rail based on the table.





Next, place the razor saw against the end of the inside rail and at the cut point of the outside rail.

Cut through the outside rail and center rail:









Position the rail on the ends and tighten the tie plate clips with pliers:






File the center rail grove back to original length so clips will fit flat.








Crimp ends with needle nose pliers to get a tight fit of pins.





















Cut off the tabs and pins flush with the tie plate ends on all sides.






Assemble the pieces and check against the arc drawn on the paper at all places,

especially along the joints. Write the Diameter on the tie plates (47 in photo)







Place track on layout and begin to screw it down while using the arc as a guide:





Checking for smooth curve across joint:



.

Last Updated on 11/21/2006
By Lyle Leverich