Joining modules

Aligning layout modules seems to be a pretty important thing if you want trains to be derailment-free across the joins. I started by joining the modules together using 8mm bolts and T-nuts in the module faceplates. The T-nuts on one end of each module have the threads drilled out so the bolt tightens the two modules up against each other. I'd thought that this would be accurate enough, but I noticed after taking two of the modules apart that there was a tiny little bit of play. I managed to line things up manually and then tighten the bolts. But I think I will drill some holes and add some alignment dowels to help in the future. It is not like I'm pulling the layout apart a lot. It's a home layout designed to move instead of a dedicated show layout that moves all the time.  

The other thing about the 8mm joining bolts is that each T-nut is part of the wiring bus, having a positive or negative bus wire soldered to it. So when the bolts are in place, they carry the power between the modules, meaning I don't have to worry about wires hanging down or making other connections. 

To keep the rails aligned, I've also glued small brass plates at the end of each module and soldered the rails to them. I've seen people use PCB for this purpose, but I don't have access to a reasonably priced supply, so I used brass sheet, of course making sure I cut the plate in half after soldering and glueing to prevent short circuits. So far this is working well. All my trains are crossing all the module joins nicely and smoothly. Hopefully, once the rail and ties are painted and ballasted the plates should blend in much better than they do right now.

Brass end plates where the modules meet.