Lionel KW Roller Repair

Just pinch the end flat with a set of pliers. Not as neat as a proper rivet die set, but very accessible.

Some just crimp them.

Others solder.

http://www.tranz4mr.com/KW_Re-Build.html

I have a small C-Clamp that I ground a point on to flare the rivet.

-Jim

I just solder the head of the rivet to the arm.  Just make sure the rivet shaft that sticks through is not so long it hits any thing else. The rivet can not be properly set with out removing the arm, giving access to both ends of the rivet. This makes a quick simple repair much more time consuming. 

Jim Harrington posted:

Some just crimp them.

Others solder.

http://www.tranz4mr.com/KW_Re-Build.html

 

I have a small C-Clamp that I ground a point on to flare the rivet.

 

-Jim

C-clamp.  Another thinking outside of the box idea and C-clamps are cheap.
D.

Hartman posted:

 

 

I have a small C-Clamp that I ground a point on to flare the rivet.

-Jim

C-clamp.  Another thinking outside of the box idea and C-clamps are cheap.
D.

It works good for coupler rivets too.

Did one today. I used my brakeman riveter set to spread the rivet. Rivet was not long enough to crimp. You can get an automatic center punch and file a tip the way you want it. I also did a new cord while I had it torn down.

Cotter pins, make sure the head doesn't strike anything. try to orient the smooth curve of the pin to the spring pressure.. You can use softer brass/copper pins for an easier install.

Screw threads will eat the roller, a flathead shoulder screw might work though.

The big no-no is bending an arc into the rivet; = bent axle stub.  They bend easy. Check, double check, and check a week later that the rollers actually roll and NEVER hang up and slide, even slightly.

Buy three rivets and two rollers for each side too. Breaking a new roller is almost as common as a warped rivet. (These are pocket change priced, literally)

If the head of a cotter pin hits, squish its head down or bend it to the side.

I have replaced several hundred rollers on ZW transformers that I have repaired. I take a pair of needle nose pliers and crimp the lower end of the pin. I have never had anyone come back to me and say the pin fell out.