I am in the process of making some semi portable ground level 5" track. The rail section is 30 x 6mm hot rolled mild steel welded onto 20 x 6 "sleepers". The first 15 m of straight track was fairly straightforward. Now for the first curved section. I have decided to make each 90degree curve to an outside radius of 4.775m. Each 90 degree section will be made up in 3 sections of 2.5m long – again for portability. To get a smooth curve I am rolling 3m lengths, there will be approx 1/2 meter of scrap each end of the curved sections – I am sure these bits will be used along the line somewhere.
First job was to make the rail bending rollers. Fortunately I had 4 nice big ball races from Austin 7 crankshafts which in pairs made the form rolls and a chunk of round Al Alloy to make the pressure roller. Once made I was surprised just how easily the 30 x 6mm section was rolled to the right radius. What I didn't expect was that the steel supplied was obviously from different lots! This meant slight adjustment of the pressure roller at times.
This is the progress so far:-


Bit of a dark photo showing the arrangement of the 2 sets of ball races and the Al alloy pressure roller. The handle was an old gudgeon pin from somewhere.

6 off curved rails ready for cutting and welding to the sleepers. My metal merchant kindly chopped them all to length (70 of them) and all I had to do was drill the 140 6mm screw holes into them and de burr the cut ends.