If you could, could you make a sketch of the type of modifications that need to be done to rails? I've been following these rail discussion on here since they first started, and seen all the pictures of your work and Glen's, but its still hard to visualize whats going on.
Maybe a cross sectional sketch of an existing stock rail, and what material gets removed/added/changed to make the rail work with a new modern cushion. Like a before and after sketch.
Also, there is a fundamental question(s) on why this is done. You alluded to before the tables you do this on are very old, and the replacement cushions available today does not work on them without extensive modification of the rails. Is this the only reason? Glen mentioned in some of his posts that brand new GC5's aren't even good and/or consistent. It would help give us perspective on why this modification is done, and when is it needed.
I'm not a table mechanic, but have been a woodworker all my life, along with a wanna-be pool player. These topics really interest me, and I'm sure others.
Thank you for taking the time to share your ideas and experiences with us.
I'll take a stab at answering some of your questions, but without giving up to many details. There's a certain consistency that gives a repeated response, meaning a sub-rail thickness of (X) along with a bevel of (Y) gives you (Z), a repeatable nose height. Just because a cushion is at say a 1 7/16" nose height, that don't mean that all pool tables with a nose height of 1 /7/16" are going to play the same. What's been lost over time through manufacturing is where the back of the cushion starts out at, as that has a major factor in how the nose of the cushion is going to react, meaning just exactly how the rails are going to respond on a pool table using say a K55 profile cushion. What Mark and I do, is set the sub-rail thickness to a known (X) thickness, and with that thickness sub-rail, only a bevel of (Y) will set the nose height to our desired nose height for the playability we're looking for, and regardless of what set of rails we're working on, the process is repeatable, as well as the overall outcome of the rails. We've done a lot of R&R in this area over the last several years, which has lead to the development of tooling to repeat the process of rebuilding the sub-rails with more and more accuracy.
You mentioned the GC5's, and you're right about the rails on them being inconsistent, but that inconsistency started way back when Brunswick started using a laminate for the finish of the rails, as that added a little more thickness to the rails, thereby changing the placement of the back of the cushions and its relationship to the nose of the cushions, meaning the body alignment of the cushions. Then to top it off, Brunswick changed their cushions from the Monarch cushions to the Superspeed's, which are not directly interchangeable with one-another, though most table mechanic's wouldn't know the difference anyway, which is why so many GC's in pool rooms today play so bad. Then, to top it off, Brunswick changed the Superspeed cushions again along about I think around 1978'-80' or so. The width of the cushions have changed from the Monarch K55 Profile having a top width of 1 1/8" wide to the first Superspeeds being 1 1/8" wide, then the Superspeeds changed to 1 3/16" wide, then changed again to 1 1/4" wide, which is why today they're not a straight change over on any Brunswick built before the second edition GC3's, because the nose height in relation to the sub-rails are off, the width is wider than what's being replaced, and you can't use a K66 cushion which is 1 1/8" wide to replace a set of Monarch cushions that are 1 1/8" wide because they don't share the same sub-rail bevel to set the nose height correctly.
This is where Diamond made the change to their rails, which is what created the Blue label rails, they're the same rails that Diamond has always been building, but what I showed Diamond how to do was to re-align the cushions on their rails to play more smooth so to speak, a little less speed, more truer banks and so on.
I know I haven't answered the questions in a way that you would have liked, but Mark and I have a lot of time...."years" invested in what we know between us, and I'm guilty of teaching other table mechanics some of these tricks of the trade, but never-the-less...I've never taught anyone everything I DO know, and the only person that does know everything I know about working on rails and tables.....is Mark, as we share all our thoughts back and forth about working on rails, new ideas...and old ones as well.
So, I guess what I'm trying to say is....there's a few things Mark and I are going to keep private, not meaning to offend anyone...but, that's they way it is:sorry:
Glen