“Cost” is a funny thing. There is material cost, and there is labor cost. Yes, going to a smaller rail profile will probably decrease costs some. But I do also feel that the ability to ‘just throw some track down on the grass’ and run trains, as my club is about to do this weekend at a show, will definitely not fly. Typically as material costs decrease, labor costs increase. Yep, Code 150 rail might work in terms of pure functionality, but is it practical in that the additional cost it the maintenance time going to make it worth the dollar savings up front.
Some considerations that might help make smaller rail more feasible would start with a much improved truck. IF our trucks were PROPERLY sprung and equalized (which most are not) we would reduce derailments considerably by not giving one wheel flange the ‘leg up’ climbing over the rail due to the natural tendency of the rigid truck to do a three point stance on less than level track. If the trucks were made to simply equalize better would be a monumental improvement. The springs in the trucks would also need to be better matched to the weight being placed on them. I have a couple of Hartford Products trucks (older ones) and they do very well in both departments, even though the springs could be just a bit lighter. This would be an improvement regardless of rail size.
Tighter standards, either by the manufacturers or the modelers, maintaining proper wheel gauge would be the next thing. I know that most modelers I know of don’t check the gauge of the wheel sets, and if they do it is only with someone’s mass produced gauge which I have found to be marginal in accuracy tolerance. This is compounded by every manufacturer seems to have a slightly different wheel contour, flange thickness, flange depth, etc. Large scale seems to be the only scale/gauge that uses the back to back of the wheel set as a point of measure. Even if the manufacturers maintained perfect gauge, the differing flange thicknesses varies the back to back. I digress…
Now to the most important part of this equation. The track itself. The smaller rail size would also require the manufacturer/modeler to be much tighter in tolerances in track laying. Higher tolerances in switch construction would be required. I think you get the idea. Just reducing the size of the rail to reduce cost is not necessarily the best answer. How much cost in labor is the modeler willing to invest to maintain a functioning railroad. I think the increased labor on the modeler’s part will reduce the pleasure part and therefore have an overall negative affect.
Just my thoughts on going ‘TOO Small’ with rail.
Bob C.