Kozo K27 Spring Rigging

The leaf springs for this project are being made from phosphor bronze to provide some "spring". The 12" x 12" x 0.05" sheet has been cut into strips using a metal slitting saw. December 3, 2017.

The individual leaves have been rough cut to length. The top portion is the leaves for the trailing truck with 8 per stack. The bottom portion is the driver leaves with 9 per stack. December 3, 2017.

The leaves have all been finished to the final length and a couple of drilling jigs have been made to add the holes to the main leaves. December 13, 2017.

The leaves have all been drilled and put together with a center pin. The top two are for the trailing truck and then we have four sets for the drivers. December 23, 2017.

The bands for the driver springs are starting to take shape. All that is left is to radius the ears and then cut the rocker that will be pinned at the bottom. January 3, 2018.

Sample of a driver spring with completed band. January 7, 2018.

After a long break due to other priorities all of the springs have been assembled. The bottom two are the special ones for the trailing truck. April 2, 2018.

These fabricated pieces will be the start of the driving box saddles. Each was made be bolting two pieces of plate to a bar and then silver soldering the joints. April 8, 2018.

Six of the driving box saddles have been cut to size and some preliminary shaping has taken place. Two of the saddles are slightly longer than the others and will be cut out of assembly at the left. April 8, 2018.

The driver box saddles have been drilled and tapered. The final step will be a more aggressive taper at the bottom followed by rounding around the spring mounting hole. Note that the saddles are shown upside down in this shot. April 29, 2018.