Is a fully enclosed connector required?
Yes the holes are massive and unfortunately that's how you connect to hot wheels track, not much can been done with this.
Admittedly my last interaction with Hot Wheels tracks goes back some 50 years, but don't the inserts slide into L-shaped notches on the bottom of the track? At least when printed in the flat (normal) orientation, this might leave some room for automatic or modeled-in supports for the top of the slots.
and miscellaneous other tech projects
He is intelligent, but not experienced. His pattern indicates two dimensional thinking. -- Spock in Star Trek: The Wrath of Khan
the connectors are wide and generally long
Yes that's correct, the connectors are wide and generally long like that link.
You do connect underneath for hot wheels track
You do connect underneath for hot wheels track and it's the same design I have implemented in my piece however this pieces is part of a 180 degree turn.
Good memories
This thread brings back the memories of playing with my son. It has been almost 20 years, but I remember these connectors.
Did you fix your print?
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Chuck H
3D Printer Review Blog