In the 1931 issue of Modern Mechanix magazine there is a 4 page article on how to make your own toy train track. It is amazing how involved the home craftsmen where back then.
http://blog.modernmechanix.com/2008/09/11/home-built-tracks-for-electric-trains/
I think during WW2 some people were cutting up tin cans to make into rail.
Modeling the "Fargo Area Rapid Transit" in O scale 3 rail.
Many years ago, I made a crossing out of two O-27 curved sections. It worked well. I also made a Y switch out of O-27 curved sections, and made two O-31 manual switches. I still have them, but haven't used them in many years. When I can buy 022 switches for $4 or so, making switches is not practical.
One thing the article shows is that a lot of fun is in the making of things.
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