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.

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, 2018.

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 27, 2018.

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.