All:

  Here are pictures of my metal track (Generally patterened from M60
track).
I was looking to use aluminum for the tread segments, but for this
prototype, I used PVC plastic.
The segments are .25 X .75 long  X 1.5 wide. It looks like the drive
lug spacing is too close, so I'll increase the tread length from .75
to 1 inch.
The pins for this prototype are brass, but stainless steel will be
used later.
The pins are .125 inch, and will be held in place with tiny, .125"
retaining clips ($6 per 100) and a groove on each end of the pin.
The PVC is plenty strong, and rubber pads will glue well to PVC, also
PVC is a good bearing material.
The alternative is to use aluminum, and cut a slot to glue the rubber
pad in.

It looks like it will take about 1 hour per inch of track to build (I
have all manual machine tools).
It looks like it will cost about $.80 per inch of track.

The track is guite flexable in two directions (forward flex and back
flex), but very rigid in all other directions.

Design drawing:
http://i192.photobucket.com/albums/z65/mm123521/Track_Array4.jpg

http://i192.photobucket.com/albums/z65/mm123521/HPIM0933.jpg

http://i192.photobucket.com/albums/z65/mm123521/HPIM0935.jpg

Very flexable:
http://i192.photobucket.com/albums/z65/mm123521/HPIM0936.jpg

http://i192.photobucket.com/albums/z65/mm123521/HPIM0939.jpg

http://i192.photobucket.com/albums/z65/mm123521/HPIM0938.jpg

Mark

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