Track Seems - Solutions

I've noticed that the seams of the newer 12" sections of orange track(w/arrow holes) are actually pretty smooth. I have older orange track sections that obtrusive seams.

what i did with old orange track was to measure the width of the ends, 1 5/16" and 1 11/32", mark arrows toward the narrower end, file a bevel into the upper end of the siderails, and store with elastics around the lower / narrower end ...
the stuff is like memory plastic... i tape the sections together, and store them on a flat surface .. we've all had long time loop d loop sections that never flatten out... also the very early track has a raised ridge along the upper outside edge of the siderail...

I've started to use electrical tape to join the segments together at the walls. Orange tape so it doesn't look so hacky. I haven't found that the tape interferes or anything but it is a bitch to peel off the tape when you have to put up your track.

I've often wondered if you can melt the walls of a track together somehow, creating your own seemless section but that might be a bit more trouble that it's worth...but fire is fun.

The shorter segments do seem to have less wall issues but then you have more seems overall because the segments are shorter. My strategy is to have longer segments for less joints total than the other way around. Less chances for trouble then...and less places to tape should you have to do that.

electricians have plastic welders for conduit..a.big glue gun... don't know if the weld is sandable...conduit is a thicker wall than the track......
but with a small sheet metal break you could make tapered channels[unions] [ narrow end up hill ] and you could also build the connectors into the unions...include a slight drop off from each upper section, while holding the track down and the siderails in place... the unions are easily anchored to the track's wooden / steel base... MAKE THE SPARKS FLY !