Hello, I had set up a new Realtrax layout for the holidays, with passing sidings. I noticed that when the train would pass into the passing siding, the switch(s) would start sparking and buzzing like crazy. Removing the train, and placing the lighted caboose on the track with power turned up, one could see easier the same thing going on. It turns out that the non-derail rails are butting up so well to the next piece of track, that the entire siding was connected to the non-derail short rails of one or both of the switches. On some, the Main line did the same thing. Now I had seen that some people had used black tape between the rail joints to fully insulate the joint, but this is kinda ugly, and can wear out after repeated passing by the train. The simple solution is to get out the old dremel tool, and cut 1/16" or so off of the adjoining track rail that abuts to the inside non-derail rails. To O gauge a 1/16 gap is nothing, especially when you figure a 90 crossover has 1/8 gap or better. Just make sure you cut the 'cheaper' piece of track, leave the switch alone - if you need to sell the switch later, someone else might not appreciate the rail being cut, but a $3 piece of track, not a big deal.
Excellent idea (gonna use it next year). As a Christmas carpet guy, I end up with particle board under my switches for support. This minimizes the effect your describing (the weight actually folds the joint, inducing the issue.) Another fix I found this yr. I bought 2 consecutive switches that consistently wouldn't throw all the way to one side. When I opened the first one, my wife said "That little safety pin like thing doesn't look right". I said "Hmm, I bought it yesterday, it's going back". Thankfully my LHS took the return. Second one, same problem, but I just moved the spring and it worked all season. To find what I'm talking about, take the bottom off the switch. There is a pin sticking out of the bottom of the point support. There should be identical springs pushing on either side of the pin. In my case, one of the springs popped off and looked like an open safety pin.
