First up, PECO insulated rail joiners. We keep having problems with these - join two rails with a standard joiner, its fine. Join them with an insulated joiner, theres a half mil step in the track. Is this a common thing, or have we just got a bad batch of joiners? If it is common, whats the usual method of dealing with it? Put up with a half mil change in height every time we need an insulated joiner? Throw them in the bin, dig out a dremel, and cut rails to insulate things? I dont mind doing that, but I'd need to insulate between directly connected turnouts, which are a little expensive to take a dremel to if I have a less destructive option.
Also, this layout includes a double crossover comprising 4 turnouts and a diamond crossing. I'm no rail expert, but I've never seen a track formation like that in reality. Is this entirely unprototypical, or does it exist on real lines?
Finaly, while we cannot presently use DCC since a number of our bachmann locos cannot easily be converted, we do plan to convert to DCC eventualy. What can we do now to enable us to make the switch without ripping up 30-40 turnouts to convert them to DCC? They are PECO code 75 turnouts.