Kozo K27 Driver Components

My build of the Kozo K-27 started with cranks for the drivers. The cranks would be machined from 3" x 3/4" discs that were picked up at the local metal supply shop (priced by the pound).

The first machining step was to create the hub on the back side. Then the axle hole was drilled and reamed to size. The disc was then re chucked to finish off the other side and finish to the final diameter. Finally the crank shot hole was drilled and reamed to size. December 23, 2013.

All of the blanks have had the first milling step performed to give them their rough shape. This was done in pairs in the mill vise with pins inserted through the holes to align them at the proper angle. December 26, 2013.

The next step was to mill the flats at the crank pin. December 29, 2013.

The next step was to mount them on the rotary table to radius the crank end. January 11, 2014.

All eight cranks with the small radius completed. Jan 11, 2013.

The next step on the rotary table was to transition the crank into the 16 degree angle. Jan 18, 2014.

The #1 and #4 driver cranks need some additional work. In this shot the backside of one of the cranks is being profiled using a fixture on the lathe. Jan 22, 2014.

Backside profiling is completed, Jan 22, 2014.

Profiling the front side of the cranks for drivers 1 and 4. Feb 2, 2014.

Facing and boring of the drivers starts. I'm still trying to decide whether to profile the tread as designed or modify to fit IBLS for 3.5" gauge. If I take 0.027 off of the backside of the tire, but leave the center hub as designed, it would take the flange down to 0.091 instead of 0.118. The back to back spacing would be 3.282 instead of the as designed 3.228. March 2, 2014.

All of the drivers have been faced on both sides and bored to the axle diameter. June 8, 2104

Next up is turning the drivers to the flange diameter using an arbor that was machined up. June 14, 2014

All of the drivers have been been turned down to flange diameter. Next is to create the tire tread and flange profile. June 14, 2014

The tread has been turned and tapered and the flange is now roughed out. Next up will be finishing the flange profile. June 28, 2014.

The driver castings have been pretty good with only one visible void found. Fortunately it is in a good location on the back side of the driver. June 28, 2014

The flanges have been shaped and the treads polished. July 19, 2014

Driver and crank being fitted to an axle. July 27, 2014

The axles are starting to come along. Aug 3, 2014

Really taking shape now with four axles turned. August 9, 2014.

Starting to slice the driver boxes off of the loaf of brass. August 17, 2104

All of the main bearing blanks plus some spares have been sliced off the two loafs of brass. Next up will be facing them on the lathe and then boring the axle hole. After that they will need to have slots on the sides to slide onto the frame. August 24, 2014.

The driver box have been finished to size and are now being slotted to slide into the frame openings. September 1, 2014

Driver Components Page 2