I've had a great many questions about exactly how to build a PVC Roller Coaster. Here is the first of what I suspect will be many, many answers!
• Use 1 1/2" Diameter Schedule 40 PVC, mostly in 20-foot lengths.
• Use 2x4 lumber (which is actually 1.5" x 3.5") for the ties (cross braces)
• To make an 18 inch wide (gauge) track, first cut the ties to 15" lengths, then use a 1 and 7/8 inch diameter hole saw or forstner bit with a drill press to "cove" the ends of the ties.
• Use 3.5 inch long #10 deck screws with a T-25 torx fitting to fasten the PVC rails to the ties.
• Set the screws at a 45˚ angle to the top dead center (TDC) of the rails. This will allow the road wheels (top) and the guide wheels (side) to roll smoothly across the rails without contacting the screw heads.
OKAY - That's the deets, peeps!
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