Great - more Sealab parts.
Yeah. Fun.
As for the treads - The tread system on the early Tamiya 1/16th scale RC Shermans were a ***** to put together. The treads were two little rods with a middle tooth and you had to put them together one at a time using clips at the ends of the links. (The later issues of the kit offer a realistic and pre-assembled tread made out of ABS that in no way resembles the original.)
Per Lorne, the treads were assembled, though at a shorter length to fit around the bogies. To create the treads themselves, he used a nibbler (a tool that creates a small square hole that machinists use) to notch out a piece of styrene or aluminum (he didn't say which). These notches are on the insides. On the outsides of the treads is a little detail part making the edge of the tread look a little thicker. Actually, it looks like a grouser (or extender) that was bolted to an actual tank's tread to improve traction on a muddy /snowy surface. Might be a kit part, I don't know. This tread piece served as a master that was molded and then used in the injection molding machine they used for other detail parts on the show. They were cast up and then attached to the treads of the Tamiya kit.
My thinking for a static version (and that's all I'll comtemplate) is to approach it like a link and length model kit setup. Cast up several individual parts, lay them out in a straight line and mold them. That piece becomes the length. They can be used for the top and bottom runs. The individual links can be used to negotiate the curves around the wheels. Though the inside of the bogies reveal the model parts, I think we could easily install another detail plate like the outside and get away with it.
Gene