I am trying to develop a method of track building which removes the need for routing. I have noticed that the cars stick well to a 0.1mm feeler gauge. It might be possible to go thinner than this, particularly if you use a larger magnet in the guide plate.
I am going to order some shim this week and try this out. 0.1mm shim steel is quite cheap when you buy it as a roll in a tin and can be cut with scissors. Shim stock in a tin is usually 6" wide x 100" long. As you are cutting this lengthwise in say 5mm wide strips you get a lot for your money (A tin is about £10.50). Also using the full width, by careful use, you can cut bends in quite long sections from the sheet which removes the need for "Pie Cutting" to turn a corner.
It would be a simple case of just gluing it to the baseboard. I believe with some textured paint it might be possible to hide this on the track without filling each side with paper. If this is required, ordinary A4 sheet paper is about 0.1mm thick.
Lane changing should be improved as there is no gap for the car to come adrift. see the image below.
The white lines in the image are an overlay of Drifter2's proposed wiring method. The shim design is shown in solid grey. As I can see it the plates should be functional in both directions and easy to lay. The force pulling on the car is also consistent as it operates across the whole width of the magnet. With a little more room for the wire follower to drift we may be able to add in two magnets one behind the other to give greater downforce for the heavier cars we are developing.
If this works it opens up many possibilities that I want to explore such as wide sections of steel shim track to give multiple racing lines, two way lane changing, T junctions and crossroads.
It would also be possible to have the lane changers laser cut in large quantities to a consistent design or even made using PCB / brass plate etching methods.