< Equalizing System 2 >
There are engaged washers at both ends of the leaf springs. Upper and lower washers are engaged with round surface, so as to make it possible to swing. The engine needs 24 pairs of the washers, including the leading truck. I prepared home made cutters to mass-produce the washers.
The cutters are made from 10 mm carbon steel rod. The photo shows turning the cutter blank with a home made roundnose tool. The cutter's section was drawn in CAD and calculated to a coordinate table in 0.1 mm pitch. Then the tool was inched according to the table. Finally the cutter was ground with fine files.
After milling the recess for blades, the cutters were hardened by propane torch and tempered in electric furnace. Then the blades were ground with oil stone. I need two cutters for upper and lower washers.
I started with the upper washer. In the lathe, a brass round bar is drilled in a desired depth. Then the job is transferred into a machine vise on a milling machine and cut section of the engaging side by the above cutter (photo). Finally it is parted off in the lathe.
The lower washer is made from a brass rectangle bar, so it is started in four-jaw. Procedure is the same as for the upper washer, except forming a projection in back side with a parting tool just before parting off. The projection is for press-fitting.
The lower washer is press fitted into the top spring and soft soldered for reinforcement. The photo shows reassembled leaf springs. The bottom one is a washer for the trailing equalizer. It was made from round bar and has long projection. The projection was glued into the casting with Loctite, because cast iron is difficult to soft solder.
The photo shows laser-cut links crossing over the main frames. I just drilled holes in precise distance.
Pins for the links were turned from steel round bar. They are fixed with washers and small cotter pins. The pin's diameter is 1 mm.
The trailing spring holds a slipping disk against the axlebox of the trailing truck. The disk is made from cast iron with gunmetal slipping ring. Note the recess around the hole, so as to hang the disk with a bolt from the bottom.
The square piece above the disk has screwed hole for adjusting projection of the bolt. The bolt is adjusted to let the disk swing freely.
The equalizing system was completed. I was tired from making many kinds of mass productions...
The photo shows close-up of the engaged washers. The double nuts adjust the engine height.
Only the last pair of washers is fixed with a cotter, instead of nuts.
Two dummy bolts are fixed nearby both sides of the spring saddle. The bolts jam the saddle between their heads.