Bob,
Not sure about the flange arrangement as yet. Model owner would like the model to negotiate 5' radius. I think some of the drivers will have to be blind. The easiest thing would be to follow Lionel's approach. I am quite sure that would work but it would not be prototypically correct but neither would the real engine ever be seen negotiating tight curves equivalent to a 60" radius. As I am sure you know the real UP engines started out with the 4th driver blind but the railroad found that it was unnecessary and the locomotive wound up with all drivers flanged!
As to your other question, I make so many different sized driver tires during the course of a year that a screw machine would do me no good. I turn out a couple of dozen tire blanks at a time on my big lathe and fit what I need to the driver centers of the model I am working on. Spares go in a coffee can for possible future use and they usually get used in a short time. I don't waste much steel tubing.
You would be correct to assume that the process of machining drivers is not something I enjoy doing anymore but I buckle down and get the job done in short order once I start the process on a model.
No one seems to want Atlantics or Pacifics converted. I see mostly large engines in the shop with lots of drivers! When I get a small locomotive to convert it seems to go very quickly! I just finished a Lionel N&W Y-6b.
Joe Foehrkolb
Joe Foehrkolb