K27 Spring Rigging
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.
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.
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.
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.
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.
The driving box saddle pins have been
machined which attach the leaf springs to the saddle boxes. The rods at
the bottom have been threaded and are part of the spring hanger
assemblies that will attach to the ends of each leaf spring. July 21,
The two piece spring hanger assemblies
have been silver soldered together and drilled through. The larger
diameter section of each needs to be cut to length and then a little
cleanup. The top two threaded rods require a U shaped connection point
for the front equalizer for the lead truck. July 22, 2018.
The spring hangers have all been
finished to size including the two special ones for the lead truck at
bottom middle. The rocking washers that will sit on top of the leaf
springs have all been cut out but still need to be drilled and
chamfered. July 19, 2018.
The rocking washers now have the 15
degree chamfers on the under side to allow rocking and the bottom
corners are chamfered at 45 degrees. Two of the trailing truck
equalizer hangers have been machined with 2 more to go! August 5, 2018.
The trailing truck equalizer have been
cut out with a test of the trailing truck leaf springs and equalization
hangers in the rear frame assemblies. Lots of spring hanger pins are
being grooved to accept E-clips. Four of these pins and e-clips have
been installed at each end of the C shaped pieces above the rear axle
opening. August 12, 2018.
The transverse equalizer has been cut
out of 0.125 thick stock. This will attach to the front of the leaf
springs on the lead driver and the center hole will attach to the lead
truck equalizer. Note that the spring hangers will actually point up
when assembled. August 16, 2018.
More spring hangers have been silver
soldered and need to be drilled and rounded at each end. Lots of pins
have been slotted for E-clips. August 19, 2018.
The spring hangers have all been drilled and shaped. Each of these
pairs will use one of the thread hangers finished earlier as shown at
the right. All of those little pins will connect the spring hangers to
the pivots on the frame and attach the upper threaded hangers. August
These are the equalizer fulcrums that
mount below the frame between driver 4 and the trailing truck. They
have been machined from an approximately 3/4" square block of steel.
September 1, 2018.
This is a frame filler piece that
provides the pivot point for the driver equalizers and also a mount for
the brake hangers. Only three more to go! September 2, 2018.
The frame fillers have been bolted to
the left frame and note the previously machined fulcrum mounted below
the frame at the right. A few spring hanger have been lain across the
frame to show how they will be positioned. The frame still needs to be
drilled for the hanger attachment points between drivers 2 and 3.
September 3, 2018.
This equalizer hanger is located
between the frame rails ahead of driver number one and connects the
lead truck up to the equalization fro drivers one and two. A small
retainer still needs to be made that will attach at the two threaded
holes in the center. The retainer keeps the leading truck equalizer
from slipping out of the hanger. September 7, 2018.
The leading truck equalizer has been
cut out from 1/8" stock and is shown here with the lead truck bistle
post and hanger. This equalizer will pivot at the bottom of the
cylinder saddle assembly. September 8, 2018.
The eight spring hangers that are used
between drivers 2 and 3 have been machined. Four of them have been
installed on the left frame rail with the remainder to be installed on
the opposite frame rail. September 15, 2018.
The next step is to make the
equalizers that sit under the frame between driver four and the
trailing truck. These need to be bent with a .375" offset since the
rear frame is offset from the main frame. A die has been made for the
vise to help with this bending process in which the metal will be
heated. The blanks for the two equalizers are at the bottom and made
from .125" stock. September 20, 2018.
The rear equalizers have been bent
using the templates above and then machined to the correct shape.
September 23, 2018.
This radius bar bearing technically
doesn't belong in this section but when I started putting all the
pieces together I discovered that I had no way to attack the trailing
truck! It seems that I never made this piece back when I was working on
the truck so I had to crank it out. September 29, 2018.
A view of all of the pieces assembled to get the driver all axles fully
sprung and the driver boxes no longer hitting the top of the side
frames. September 29, 2018.
The equalization is set up so that
front three axles are interconnected and tie to the frame behind the
second driver. September 29, 2018.
The rear three axles are
interconnected and tie to the frame in front of the third driver. The
rear end of the trailing truck leaf springs attach to the
rear frame extension. September 29, 2018.