I finally broke down and bought a 3D printer. While searching through “Thingiverse” on the web someone posted 1/6 scale M5 Stuart tracks. I downloaded the file and printed them, the seem to fit OK so I made my own files using measurements from the on line models (my track pads are only rectangular, the on line models have more detail) for a proof of concept. Will 3D printed tracks work?
I used flexible filament for the track pads, printed the guide horns as two separate pieces in ABS (PLA is too brittle) and started to print. It took forever as there are 65 or 66 track pads per side, double that for the guide horns or end connectors and then double that for the screws I used to secure the end connectors to the pads.
My first thought was to make one side with ABS end connectors and one side with metal casted end connectors with the thought that ABS would be tough enough. After casting a few I realized the metal ones would be very heavy so I proceeded to make both with the ABS parts. The picture above shows one with metal connectors the other with ABS (gray). They are secures to the pads with nylon 4-40 screws (for weight I used nylon). I bought two different screw types to see which works better.