If the repair results in an income that's more than the price of the repair, then it is worth it. This is not the first time this repair is done in places like this and they keep on doing it so therefore, the repair is worth it.
Amazing Teaneck you are a very smart man. I've never seen some body do that before. Thank you for teaching me. Thank you again. I look forward to seeing what you finish again.
Горемастер, на такие штифты зубы в челюсть садят, вся эта херня что он напаял из разного метала - развалится, такой ремонт в народе называют - из говна и палок.
i didnt know what to expect ... selling machinery like this and seeing gears broken like this and the cost to repair/ replace the parts and to see this same repair done.... great job
An interesting soluition to an annoyingly common problem. I saw you had previously repaired that gear and since they held up, I know the repair will hold. Very nicely done!
@@howardosborne8647 You really think replacing the hardened steel teeth of a gear which couldn't bear the stress and broke with copper teeth will hold?
In Gosport, England, there is a submarine museum. On display, they have a large bronze bevel gear, which belonged to a WW One submarine. This gear drove some vital piece of equipment ... I forget what the machinery was. A number of teeth were stripped from this bevel gear, and the result was the submarine was unable to surface. The submarine became stranded on the sea-bed. Artificers on board, drilled and tapped holes in the gear, in a similar way to what you have done. They then filed new teeth on the gear, such that the machinery was able to be put back into operation ... and the submarine was able to reach the surface. Talk about 'being under pressure'.
I live in Gosport, and have seen the item in question. The story is close - although the gear was repaired using deck plate. The gear was part of the drive train and prevented the submarine moving under power, but she wasn't stranded on the sea bed. The repair held up until a replacement part could be shipped out to the submarine.
Have to guess that the broken gear was part of the operating mechanism for the fore or aft planes; the wing-like projections that allow a submarine's "angle of dangle" to be controlled.
Reminds me of back country trail repairs. Sometimes the fix only has to last a little while, but I have temporary fixes outlast the original part. Good for these guys for not giving up and abandoning the project.
That is just brilliant! Using the saddle of a lathe as a shaper!!!! (It just goes to prove the old adage: necessity is the mother of invention). Good job! 🤗
Is niks repareren aan en ik zal dit niet eens ergens in willen hebben want die plek is veel te zwak vergeleken met de rest. Het probleem is voor hun is dat ze niet anders kunnen of om aan onderdelen komen. Wil je het goed doen dan draai je helemaal een nieuwe. Voor ons is het goedkoper om een nieuwe te kopen voor paar tientje in vergelijking kwa werk en kosten. De oude word weer gerecycled voor andere doeleinden. Maar dit nee over half weer naar de klote.
I do same for gerbox, but use TIG and inconel filament. Can tell you truth - it`s bull shit. Teath not hard enough fore normal operation. Only to sell somebody, cause after 2 monthe of work it`s worn out.
@@davidhooper3821 you are clueless, the only decent solution for CAST IRON is silica bronze braze as it does not melt the parent material making it brittle. the issue is that its not ideal for teeth of a gear when you can braze on actual cast iron but its not as strong of a bond as again the base parent material is brittle at the joint. so depending on what is needed (duty of the gear) one or the other is good, what was done here is NOT silica bronze but rather a cast brass brazing rod and that WILL crack and is very weak as you can see by the cutting of it. what are you suggesting you WELD IT WITH? a MIG? machine Stick rods? you are so ignorant, please either elaborate or keep your dumb comments to yourself.
@@davidhooper3821 Possibly but nickel rods are so expensive any more and for a back gear I think if he takes it easy on the lathe he probably will never have a issue with his repair.
very nice! I was expecting something terrible after initial angle grinder shots, but then you got me back with cutting the right gear tooth geometry. I salute you!
I used to repair window regulators like this back in the late 70’s. I also used to call it dentistry. I was about 18 and never heard of this technique. To me it just made sense. That’s the good thing about being a kid. At the time nobody I knew had used a mig welder. So it was brazing everything
You certainly don't need to go this far to fix the skinny teeth on a window regulator, just build the weld up and re-grind the profile with a cut off wheel and maybe some files. Done it many times on antique vehicles....
Great job... using very worn out equipment! All the parts rocking around on the bed of that lathe. Good work too for making the best with what you have -- respect!!
Fanatic job well done sir!! I saw my grandpa do the very same thing to a broken gear from one of his machines. It’s nice to see something old and broken be put back into service. Thanks for sharing God bless you and yours.
this kind of idea comes out of necessity; people in Latin America do come up with some good ideas for many problems like this; here in the states, we are so used to just exchanging parts and not doing many repairs, great Idea sir. thank you for sharing.
@@evanpenny348 Because the price of lathes would far exceed the wallet of the consumer. Henry Ford eliminated expensive brass radiators and fittings from his early model T cars, so that later versions of the same model T were about half the cost to the consumer, thus triggering the Automobile Revolution. He sold 15 Million model T's as a result, which was a staggering achievement in the 1920's Nowadays the Chinese are using cheap materials and techniques to make their products so affordable, that the consumer has a terrible dilemma: _"Do I buy a reliable German machine or a cheap Chinese knock-off🤔🤔🤔"_
@@BrassLock please be careful with your suggestions! I'm from Austria, so I know pretty well what it means to buy a good car with qualitative parts build in. Today we are at a point, where not every German car has to be better than a car from somewhere else. Yeah, Chinese cars are complicated.. On one hand, they aren't seen very often here in Europe, because the search for replacements is ridiculously hard and yes, there are that many better cars, but the most Chinese ones.. But on the other hand there aren't many German cars anymore, which are build from nothing but German parts, not even cars that are mostly build from parts made somewhere in Europe.. I think more than 80% of the German cars are mostly build of Chinese crafted parts, what tells us a few things: 1. The Chinese definitely made some of the worst, but also some of the best materials and parts for different products. 2. The fact, that many cars are still put together in Germany or at least Europe, may be a big point in all of this. The controle mechanisms are very thought through and each and every part will be handled and put together with much more care, than it's the case with many other car factories in other countries and they will be combined with parts made in Europe or Germany. To spend more money will set the chances very high, that you will get a very solid German car, but don't let yourself fool by old and glorified names, because many things have changed. Today the German automobilindusrtie isn't the same as 20 ago so please.. always research! Don't buy just because it's German!
@@IlluminaAssel Everyone here has the right to express a personal opinion, provided it doesn't endanger other's wellbeing. ● A personal opinion is not a _suggestion_ for others to take action. ● A personal opinion is not _advising_ others to take action. @illuminaAssel • Please be aware of these simple, obvious faults in your discussion, and correct them when addressing me personally. Thank you.
Very good job. The tapped brass screws provided a good foundation. I've had good luck brazing cast. I like this process better than the preheating and the nie rod.
@@johngilbert6810 I think the brass would be more maluable and less likely to break like brittle cast steel. I could for any method of repairing broken cast, simply because of the process of welding cast. It's a lot of work for it to fail in the end because of a little bit of cool air causing it to crack.
I used to have an old Atlas lathe (before it became Sears Craftsman) that had a back gear pin gear like that one. It also had a series of holes on the flat face of that gear toward the chuck that you could use the headstock as a divider. There was a retractable pin that went in that fixed the position that was accessed outside of the drive housing. Your use of the lathe as a manual shaper is pretty cool. You also did good by putting in those screws in the cast iron before brazing. There is a nickel type welding rod you can use in place of brazing for cast iron. For gears, brazing is so much better. This is a nice post of this sort of metalworking trick. Thank you for posting.
I used to have a Halifax 524 lathe (read Atlas if in US), it is sadly missed, but I chose to keep my children (then aged 9 & 11) & so I lost the lathe.
Вы чё доебались "умники"? Среди всех коментов, только рускоязычные отличились своей "невъебенной продвинутостью". Бля, там люди тоже понимают, что это залипуха, но когда страна нищая и люди, быть может, последний хуй без соли доедают, или просто недоступно новое, или нет соответствующих ресурсов для качественного восстановления, то сгодится всё, что сможет поддержать работоспособность хоть на какое-то ещё время. Постыдились бы - люди хоть как-то выходят из положения, а не хуи пинают.
Normalmente estes tipos de engrenagem são de ferro fundido ou aço forjado creio q a melhor solda seria de aço inoxidável # no + 1 ótimo trabalho ( recurso muito útil )
@Fire Metal, I’m very impressed! Your whole approach to this problem was creative, great use of brazing, and turning your lathe into essentially a shaper with a rotary table is the cleverest thing I’ve seen in a long time. Best of luck on your RUclips channel. 👍🏼😁
@@jkucukov well this repair vedio should give you hope on fixing it,, you can mig are Arch weld it also,, l did a smaller gear with one missing tooth with mig and you con concentrate the weld more and not have to use screws just cut groove with cut off wheel for weld and then use a file to shape it.
Are you saying the gear teeth would be formed completely out of stud shafts, no brazing needed to make the tooth shape? I can't picture that, especially with the small amount of material those studs could be seated in. I think the brazing is just as much to reinforce that thin "rim" and the bolt shafts, as it is to provide material for the tooth profile. If the gear was the same thickness from shaft to outside flange, there would be enough meat to support the studs, but I don't see that thin flange surviving the torque on a back gear. Cast iron is too brittle for the small amount of material in that flange to hold up.
I have a Smith and Mills 17" shaper that is probably 100 years old. It has several broken teeth in the crossfeed drive gear that have been repaired, who knows how many years ago, by exactly the method you describe. The studs interlock slightly, they haven't been welded or brazed. It appears that the studs were filed to shape. The gear is pretty fine, the teeth are less than an 1/8" thick. The machine works just fine. I don't subject it to heavy use, but it was worked plenty hard in the past. I have also seen the same repair on several similar sized gear teeth on a 13" Southbend lathe. It probably started out as an emergency repair, but worked well enough that they never bothered to replace the gear. We are so used to the landfill economy and throwing everything away and buying new that people are horrified at thought of the terrible things that might possibly happen as a result of some guy in a third world country making do with what he has and repairing an expensive or hard to find part. I swear, if our knuckleheaded banksters and politicians manage to blow the world up one of these days, it will be the barefoot mechanics of the third world that pick up the pieces and put it back together.
@@haroldmedalen6757 You have no idea how right you are. I have a milling machine of the German company Biernatzki, this year it turned more than 80 years old. And this is quite a working and accurate machine, which I completely disassembled and repaired with my own hands. And this company no longer exists. Such a rarity from the past.
@somebody else Both the gear on my shaper and the one on the lathe are done with the row of studs alone. The studs very nearly overlap and it looks like they were hand filed to the proper profile. The work is very finely done. It is possible that they were both done by the same person, as both machines have been in our somewhat isolated town for many years. I haven't found anyone who knows anything about the history of the repairs. I expect they were done back in the days when we had one steamship a week, not daily air service like today. If a part was damaged or failed and you needed the machine, you would have had to figure out how to fix it and keep it going however you were able. I think this guy's repair brazing over the studs, then cutting the teeth to shape with the tool in the lathe is probably a more durable repair by far than the studs alone, but I know I could run my shaper all day without any problems from the repaired gear. (Knock on wood!)
In my trade we had bronze rod high strength nickel alloy that I use to braze tungsten teeth to 1 metre cutting wheels . These rods are recommended by the manufacturer to repair or replace missing teeth on gears and also for high strength brazing .
We did this at TAFE (technical college) during my apprenticeship and it's called "pegging". I had to do it in an emergency situation at work once to keep production going. We also made a whole spur gear from scratch at TAFE - turned the blank on the lathe then cut the teeth on the milling machine using the indexing head.
This is economically advantageous in countries where the work of a locksmith costs $ 10 for a 12-hour working day, and CNC machines have not even been seen in pictures.
Интересный способ, как я понял - шестерня из чугуна и поэтому не наплавлял элекстродами, глядя на "износ" зубьев можно сказать что это не нагруженная(об этом говорит и то из чего она сделана) шестерня а сломались из за чп какого-нить. Бронза/латунь канешь не настолько прочна и поэтому вставлены болты для усиления, зато она лучше скользит в отличии от сыромятины металлической. Думаю шанс что она походит есть, способу быть.
Absolutely brilliant as a "field repair" which was driven by necessity. Faced with the circumstances of what he had before which was "totally fuck8d-up" he now has something which, with a bit of tweeking with a set of Swiss files and engineer's "marking blue", enables him to use the machine. Is the lathe going to be as good as new, obviously not, but with careful usage he can now do things with it that in it's previous state was impossible. Necessity is always the mother of invention. Greetings from the UK !.
With all the safety regulations we have to observe here in the states...I LOVE how this machinist is sitting there cross-legged in shorts welding this gear up! Just doing what he has to.
Yep, that’s the way the Master Machinist I apprenticed under taught me. Turn the carriage of the lathe onto a shaper with a boring bar and a form tool. Waaay quicker than having a new gear made.
@@lost4468yt I'm not sure what you are trying to say the original comment was just describing the process in the video more or less saying the master machinist he was an apprentice for taught him the same method to save money instead of having to have a whole new gear made
Needing a machine up and running faster than the days to weeks it will take to get a new part in isn't that high pressure. On a decades old machine it might be the only option.
Для тех,кто не понял зачем это всё,должен помнить,что обломанные зубья шестерни из литья (чугуна),гараздо слабее чем болты из сырца и наплавленной бронзы....
Как говорится на продажу. Себе так не станут делать. Один зуб так ещё можно сделать, чтобы был перехлёст с живыми зубьями, а так при нагрузке они быстро выйдеут из строя. Но это не точно 😉
@@user-nx8tf7ci6u почитайте ремонтные работы в сельхозтехнике. Новая чугунная или стальная шестерни не всем доступны. Сейчас в серую такая шестерня обойдется в 5-6к рублей, официально даже представить страшно.
@@_MadFox Какая разница, сколько стоит эта шестерня. Есть механизм, и ему не объясниш, что денег нету. Ремонтные зубъя, сильно хуже основных. Они ослабили колесо сверлением, металл напайки, скорее всего, мягче, чем металл на зубъях. Ну вот и представте что будет. Так вообще не стот делать, если ты не на обитаемом очтрове и вокруг зомби апокалипсис, и у тебя сварочник сломался.
@@MrMad-lp7in теория, это, конечно, хорошо. Но вот почему-то мне шестерни заказывают в Краснрдарский край из Читы, из Оренбурга... Это подходит под локальный апокалипсис?
Электросварка невозможна так как это по видимому чугун, при сварке место сварки закалится и зубья невозможно нарезать. Он все сделал правильно. Имейте в виду что это ж не завод и технологические возможности ограничены. Но раньше и ваши отцы так делали, просто вы отупели от деидустриализации. Сидите за компами и даже сверла заточить не умеете.
@@weldermusk8860 Плюсую под каждым словом. Для себя отметил, что только русскоязычные отметились своей "невъебенной продвинутостью" и критикой. Ска, да посмотрели бы как в России что "умельцы" сотворяют с новой техникой и гробят её, а уж про "реставрацию" чего-то вообще промолчим. Хотя, да - не все жопорукие, но дохуя и больше. Тут люди со скромными ресурсами и возможностями и хоть как-то выходят из положения, но обязательно находятся те, кому нужно всё обосрать в силу своей ограниченности и тупизма. Да, это чугуний и чел всё правильно сделал, как смог. Зубья притрутся, а пока сотрутся или сломаются либо новое успеют заказать, либо повторят потом процесс; факт в другом - работа механизма не останавливается надолго, люди дорожат работой и временем простоя.
That bull gear looks like it's about done, it looked like it had several other teeth repaired already. One positive thing with the way you did that and having it mesh with the harder gear the softer metal will work its teeth in overtime using the squish Factor. I never thought about using my lathe as a shaper. Thanks, I learned something new. From Virginia USA
You need to have the exact same shape on every teeth, there was too much load on them because the ones that were repaired before got the wrong shape. So now another 3 gonna be broken and again right next to the teeths that was just repaired... and how exatly different metal in something that needs to have every teeth identical is a beneficial factor?!
@Biały if you are wondering I was referring to imperfect duplication of the teeth using brass would allow them to wear into the steel teeth on the other gear. That is what I was referring to.
The gear or the repair? The teeths gonna last because the shape of the new teeths is wrong so the new teeths will be underloaded, the teeths right next to it gonna breake because they gonna be overloaded just like it broke before as you can see previously repaired teeths right next to it.
Clever repair....my first boss in the machine shop once did this kind or repair with a shaper....cut a dovetail in the gear then shrank fit a plug, then formed the teeth as you have done.
These guys are masters of repair. In the West this part would have been replaced most likely with a new one. Labor costs in the West make such a repair unaffordable. This is assuming they can find workers who are skilled in this kind of work.
The gears don't exactly ride on each other like he showed.... There is a small gap between the crest/crown of one thread and the root of the other.... The way he machined it , I don't see why it won't work.... This is in a place where they have to reuse/rebuild/repurpose just about everything..... I think he did an excellent job on the repair..... Depending on the quality of the brazing rod he used , I don't see why it wouldn't last a long time. The gears are cast iron. Not the strongest metal.....
The gears are rough and ready - including the wheel he was testing it on. In a poor country a wheel is better than no wheel and if it is running at low speed ( and it will have to be ) it may last a little while - he can always tweak it if it doesn't and there is some give in the brazing rod material anyway. Last resort he fixes it again. Don't be so negative.
@@we-are-electric1445 When he test rolls the gears against each other it’s clearly visible that the repaired patch has too much material. The gear bumps up and down over the brazing. When installed onto axles with a fixed and rigid center distance there will be interference there which causes jamming or other damage depending on drive power. If he built a test jig with axles at the correct distance then he would be able to see this mistake and correct with his grinder. Tooth form will be not even close to correct by eye to irregular wear is to be expected. You are right in saying a wheel is better than no wheel. But swapping out shitty wheels every two weeks is not a solution. Engineering knowledge is available for free, with that much better results can be achieved with similar equipment.
@@user-tw9io9nz2m So go and learn some engineering knowledge before making comments on something you have no knowledge of. Machining the gear on a his lathe is far more accurate than a grinder.
@@davidcraemer8227 so you’re telling me that this man can produce a better gear by indexing gear teeth with his eyeballs compared to having a test jig, seeing where the high spots interfere and gradually removing those with some patience? The gear teeth may be the correct depth if he compared it to an original tooth on the gear before slotting but I still have my doubts about the tooth form and spacing of the teeth with literally no way to index. Look closely and you can see the gear moving while he is cutting his first slot.
For the shaping of the teeth, it will be very worth your time to deal with the slop in the toolpost, topslide, and however you had the gear fastened to the chuck. The part moved several times, the boring bar was pushed away from the gear way more than it should have been, and the topslide rocking on the carriage made me watch several times because I couldn't believe it was moving that much. The way you're going about that repair is perfectly fine, and a nice job on the brazing. But, you'll get much better results if you can fix the rigidity of the setup.
@@MsRustynuts India is hardly third world. In fact, your medication is probably produced there and the have a nuclear weapons program, ICBMs, huge industry and a vast infrastructure. You act as if he's in some African shithole...
The answer is in the video and it is very visible, next to the broken teath you have teaths that also have bronze in them and on top of that the shape of this teeths are different=the load on teeths is not distributed properly...
We all know it’s not going to last but if it lasts long enough to make a new one then excellent. Very skilled guy
It might last a lot longer than you think. Don’t be negative!
If the repair results in an income that's more than the price of the repair, then it is worth it. This is not the first time this repair is done in places like this and they keep on doing it so therefore, the repair is worth it.
You remind of an old saying. "Those that cannot do, bitch".
The original OEM one didn't last either, so what's the expectation?
@@PlasticCogLiquid complete and total failure under heavy load.
That came out considerably better than I expected. Thanks for showing this.
That is an incredibly inventive way of handling that. nicely done!
Amazing Teaneck you are a very smart man. I've never seen some body do that before.
Thank you for teaching me.
Thank you again. I look forward to seeing what you finish again.
Best gear repair i have seen. The bolts, tapping, and precision cutting! I see it is a low speed gear; I would trust this repair.
Finally. An actual usable gear repair done that isn't made from epoxy or wax that seems like it'd still be usable. Good job.
Depends on the use.
Won’t last at all, material is to soft.
@@Kk385*too soft
Горемастер, на такие штифты зубы в челюсть садят, вся эта херня что он напаял из разного метала - развалится, такой ремонт в народе называют - из говна и палок.
i didnt know what to expect ... selling machinery like this and seeing gears broken like this and the cost to repair/ replace the parts and to see this same repair done.... great job
The whole process and techniques are excellent, I learned something new today. Cheers
Very much impressed by your "root canal" metal dentistry. I like your technique, thanks for posting.
More like a post crown treatment.
dentistry haha, love that!
An interesting soluition to an annoyingly common problem. I saw you had previously repaired that gear and since they held up, I know the repair will hold.
Very nicely done!
Of course it will hold... until it's used...
@@lopezlopez7132 And hold for a long time in use. It is an school old technique well proven to work reliably
@@howardosborne8647 You really think replacing the hardened steel teeth of a gear which couldn't bear the stress and broke with copper teeth will hold?
@@alpyre pronze ...and bronze can be as tough as steel if not as hard. I would imagine some wear on those teeth ut take a while.
In Gosport, England, there is a submarine museum.
On display, they have a large bronze bevel gear, which belonged to a WW One submarine. This gear drove some vital piece of equipment ... I forget what the machinery was.
A number of teeth were stripped from this bevel gear, and the result was the submarine was unable to surface. The submarine became stranded on the sea-bed.
Artificers on board, drilled and tapped holes in the gear, in a similar way to what you have done. They then filed new teeth on the gear, such that the machinery was able to be put back into operation ... and the submarine was able to reach the surface.
Talk about 'being under pressure'.
sounds like Das Boot material
Sounds like that never happened event
@@pharaon6718 Go take a look. The museum is at HMS Dolphin, the submarine base.
I live in Gosport, and have seen the item in question. The story is close - although the gear was repaired using deck plate. The gear was part of the drive train and prevented the submarine moving under power, but she wasn't stranded on the sea bed. The repair held up until a replacement part could be shipped out to the submarine.
Have to guess that the broken gear was part of the operating mechanism for the fore or aft planes; the wing-like projections that allow a submarine's "angle of dangle" to be controlled.
Maintaining equipment is more important than repair or replacement. Good job making this gear usable again.
Your ingenuity is exceeded only by your patience. Well done.
Ingenuity pmsl seen this done in the 80s without using machinery to cut the teeth by a 70 year old pit fitter using a hacksaw and files .
What patience ?
Reminds me of back country trail repairs. Sometimes the fix only has to last a little while, but I have temporary fixes outlast the original part. Good for these guys for not giving up and abandoning the project.
There's a good chance this fix will last.
That is just brilliant! Using the saddle of a lathe as a shaper!!!! (It just goes to prove the old adage: necessity is the mother of invention). Good job! 🤗
A true repairman, not just a parts replacer . 👍
Is niks repareren aan en ik zal dit niet eens ergens in willen hebben want die plek is veel te zwak vergeleken met de rest. Het probleem is voor hun is dat ze niet anders kunnen of om aan onderdelen komen. Wil je het goed doen dan draai je helemaal een nieuwe. Voor ons is het goedkoper om een nieuwe te kopen voor paar tientje in vergelijking kwa werk en kosten. De oude word weer gerecycled voor andere doeleinden. Maar dit nee over half weer naar de klote.
I do same for gerbox, but use TIG and inconel filament.
Can tell you truth - it`s bull shit. Teath not hard enough fore normal operation. Only to sell somebody, cause after 2 monthe of work it`s worn out.
вы туалетную бумагу тоже ремонтируете, вместо того чтобы выбросить?
@@3D_Kam
Вот и я ро то самое. Мягкой латунью зубы напаять - совсем тупые.
Drilling and tapping the holes, then installing the bolts is an excellent trick for cast and difficult to weld materials. Thank you.
only for those who cant weld...
@@timothywhieldon1971 ]
That is a small gear, you can easily preheat that and weld it
@@davidhooper3821 you are clueless, the only decent solution for CAST IRON is silica bronze braze as it does not melt the parent material making it brittle. the issue is that its not ideal for teeth of a gear when you can braze on actual cast iron but its not as strong of a bond as again the base parent material is brittle at the joint. so depending on what is needed (duty of the gear) one or the other is good, what was done here is NOT silica bronze but rather a cast brass brazing rod and that WILL crack and is very weak as you can see by the cutting of it. what are you suggesting you WELD IT WITH? a MIG? machine Stick rods? you are so ignorant, please either elaborate or keep your dumb comments to yourself.
@@davidhooper3821 Possibly but nickel rods are so expensive any more and for a back gear I think if he takes it easy on the lathe he probably will never have a issue with his repair.
very nice! I was expecting something terrible after initial angle grinder shots, but then you got me back with cutting the right gear tooth geometry. I salute you!
Bardzo jest świetny ten cały pomysł pozdrawiam twórcę tego filmiku serdecznie 👍👍👍👍
Przeciez to dziadostwo daje 5 minut działania ten mosiądz nie wytrzyma takich sił jest zbyt mieki i plastyczny
I used to repair window regulators like this back in the late 70’s. I also used to call it dentistry. I was about 18 and never heard of this technique.
To me it just made sense. That’s the good thing about being a kid. At the time nobody I knew had used a mig welder. So it was brazing everything
You certainly don't need to go this far to fix the skinny teeth on a window regulator, just build the weld up and
re-grind the profile with a cut off wheel and maybe some files. Done it many times on antique vehicles....
@@onazram1
We didn’t have a mig back then
@@johnnyfannucci That would make it more difficult for sure
I fixed my electric regulators about 16 years ago. I'm still building the car!
I ended up going with full manual windows instead in my 81 Z28
Yea, in the 80’s I had no welder, so i brazed EVERYTHING!
Great job... using very worn out equipment! All the parts rocking around on the bed of that lathe. Good work too for making the best with what you have -- respect!!
Fanatic job well done sir!! I saw my grandpa do the very same thing to a broken gear from one of his machines. It’s nice to see something old and broken be put back into service. Thanks for sharing God bless you and yours.
#thereisnogod stupid
Fantastic..Not Fanatic :P
@@sajidrafique375 fanatic of orthography 🤣🤝👏👏
this kind of idea comes out of necessity; people in Latin America do come up with some good ideas for many problems like this; here in the states, we are so used to just exchanging parts and not doing many repairs, great Idea sir.
thank you for sharing.
In a throw away world, absolutely beautiful to watch
Well done. I have a lathe with a similar type of repair which has held up for me over many years. Thanks for posting this!
Great. One interesting thing however is why if a bronze repair is so all fire good why gears are not made of all cast bronze. Does anyone know?
@@evanpenny348 Because the price of lathes would far exceed the wallet of the consumer. Henry Ford eliminated expensive brass radiators and fittings from his early model T cars, so that later versions of the same model T were about half the cost to the consumer, thus triggering the Automobile Revolution. He sold 15 Million model T's as a result, which was a staggering achievement in the 1920's
Nowadays the Chinese are using cheap materials and techniques to make their products so affordable, that the consumer has a terrible dilemma: _"Do I buy a reliable German machine or a cheap Chinese knock-off🤔🤔🤔"_
@@BrassLock Good point
@@BrassLock please be careful with your suggestions!
I'm from Austria, so I know pretty well what it means to buy a good car with qualitative parts build in.
Today we are at a point, where not every German car has to be better than a car from somewhere else.
Yeah, Chinese cars are complicated..
On one hand, they aren't seen very often here in Europe, because the search for replacements is ridiculously hard and yes, there are that many better cars, but the most Chinese ones..
But on the other hand there aren't many German cars anymore, which are build from nothing but German parts, not even cars that are mostly build from parts made somewhere in Europe.. I think more than 80% of the German cars are mostly build of Chinese crafted parts, what tells us a few things:
1. The Chinese definitely made some of the worst, but also some of the best materials and parts for different products.
2. The fact, that many cars are still put together in Germany or at least Europe, may be a big point in all of this. The controle mechanisms are very thought through and each and every part will be handled and put together with much more care, than it's the case with many other car factories in other countries and they will be combined with parts made in Europe or Germany.
To spend more money will set the chances very high, that you will get a very solid German car, but don't let yourself fool by old and glorified names, because many things have changed. Today the German automobilindusrtie isn't the same as 20 ago so please.. always research! Don't buy just because it's German!
@@IlluminaAssel Everyone here has the right to express a personal opinion, provided it doesn't endanger other's wellbeing.
● A personal opinion is not a _suggestion_ for others to take action.
● A personal opinion is not _advising_ others to take action.
@illuminaAssel • Please be aware of these simple, obvious faults in your discussion, and correct them when addressing me personally. Thank you.
Very good repair ! - You used your lathe as a shaper ! - Great idea - Well done man 👍👍👍
I've done it for keyways on gears and pulleys; works amazingly well, if a bit tedious.
@@UncleKennysPlace but rewarding in the end once you've got your key way done ! :o)
Really a good idea for many unrecoverable problems like that!
Thanks for sharing!
I'm very impressed . Well done !!! BRAVO !
Honestly, watching this kind of video puts me in my place. How much I have to learn. Thanks for sharing!
Very good job. The tapped brass screws provided a good foundation. I've had good luck brazing cast. I like this process better than the preheating and the nie rod.
The screws were steel, adds more strength too.
If the steel teeth broke the brass teeth will break even sooner. Nothing to be learned here unless you have dirt floors and no shoes
@@johngilbert6810 I think the brass would be more maluable and less likely to break like brittle cast steel. I could for any method of repairing broken cast, simply because of the process of welding cast. It's a lot of work for it to fail in the end because of a little bit of cool air causing it to crack.
Finally something really interesting on RUclips, congratulations !!
Very cool process, the happy music at the end was a loud surprise lol
Thanks for sharing ...This is something I will try out
Great to see these people doing so much with so little.
Muito bom.
Excelente serviço.
Smart man, nailed that repair!
this is the best "thinking outside the box!" example i have seen in a long time!
Fabulous work bro ⚡🔥🔥
Simplesmente fantástica essa idéia PARABÉNS !!!
What a clever man you are. Excellent work.👍👍👍 Cheers Stuart 🇦🇺
That, is very clever! It just goes to show an old style can really work. Thanks for taking the trouble of making this video.
I used to have an old Atlas lathe (before it became Sears Craftsman) that had a back gear pin gear like that one. It also had a series of holes on the flat face of that gear toward the chuck that you could use the headstock as a divider. There was a retractable pin that went in that fixed the position that was accessed outside of the drive housing. Your use of the lathe as a manual shaper is pretty cool. You also did good by putting in those screws in the cast iron before brazing. There is a nickel type welding rod you can use in place of brazing for cast iron. For gears, brazing is so much better.
This is a nice post of this sort of metalworking trick. Thank you for posting.
I used to have a Halifax 524 lathe (read Atlas if in US), it is sadly missed, but I chose to keep my children (then aged 9 & 11) & so I lost the lathe.
@@pinohaxk628 Who asked you to reply so rudely?
Show de reparo,peça pronta p voltar ao trabalho!!👏👏👏👏👏👏
Old School ,well done !!👍👍👏👏👏
That´s super creative. Genious work!
Well done!
С таким успехом можно было просто пластилином заклеять и сделать зубы результат один и тот же был!
Эволюция диайвайщиков. Термоклей заменили на латунный припой.
еще и профиль зуба не совпадает,шестерня не садится
@@Samkr07 по месту притрётся!
Вы чё доебались "умники"? Среди всех коментов, только рускоязычные отличились своей "невъебенной продвинутостью".
Бля, там люди тоже понимают, что это залипуха, но когда страна нищая и люди, быть может, последний хуй без соли доедают, или просто недоступно новое, или нет соответствующих ресурсов для качественного восстановления, то сгодится всё, что сможет поддержать работоспособность хоть на какое-то ещё время.
Постыдились бы - люди хоть как-то выходят из положения, а не хуи пинают.
Мастер просто мало курнул, покурит как следует, и сделает из пластилина, как учили.
Grande mestre! Parabéns.
Fantastic job sir thank you for sharing 👍👍👍👍👍
Normalmente estes tipos de engrenagem são de ferro fundido ou aço forjado creio q a melhor solda seria de aço inoxidável # no + 1 ótimo trabalho ( recurso muito útil )
@Fire Metal, I’m very impressed! Your whole approach to this problem was creative, great use of brazing, and turning your lathe into essentially a shaper with a rotary table is the cleverest thing I’ve seen in a long time. Best of luck on your RUclips channel. 👍🏼😁
Thank You | Marc McKenzie
That's exactly what *I* was thinking too. This was brilliant in every way.
it came out really good, well done
That is just brilliant!!! Very clever.
The braze would be quite soft compared to the rest of the gear, but if it work, fantastic! 👍
That's impressive,, l buy and restore vintage lathes,, I'll never be worried about broken gear teeth again thanks for the lesson.
I got a 1911 Von Wyck lathe with a broken gear like this.
@@jkucukov well this repair vedio should give you hope on fixing it,, you can mig are Arch weld it also,, l did a smaller gear with one missing tooth with mig and you con concentrate the weld more and not have to use screws just cut groove with cut off wheel for weld and then use a file to shape it.
Excellent job sir!! Hats off to you for a perfect repair.
Great video - fantastic skill involved - well done
My boss did that to the back gear on his small Sheldon lathe many years ago. They are still using it. It's probably lasted 30 years or more.
I remember learning this technique as an apprentice, it works better with thicker studs which slightly interlock , you dont need to braze then
Are you saying the gear teeth would be formed completely out of stud shafts, no brazing needed to make the tooth shape? I can't picture that, especially with the small amount of material those studs could be seated in. I think the brazing is just as much to reinforce that thin "rim" and the bolt shafts, as it is to provide material for the tooth profile.
If the gear was the same thickness from shaft to outside flange, there would be enough meat to support the studs, but I don't see that thin flange surviving the torque on a back gear. Cast iron is too brittle for the small amount of material in that flange to hold up.
I have a Smith and Mills 17" shaper that is probably 100 years old. It has several broken teeth in the crossfeed drive gear that have been repaired, who knows how many years ago, by exactly the method you describe. The studs interlock slightly, they haven't been welded or brazed. It appears that the studs were filed to shape. The gear is pretty fine, the teeth are less than an 1/8" thick. The machine works just fine. I don't subject it to heavy use, but it was worked plenty hard in the past.
I have also seen the same repair on several similar sized gear teeth on a 13" Southbend lathe. It probably started out as an emergency repair, but worked well enough that they never bothered to replace the gear.
We are so used to the landfill economy and throwing everything away and buying new that people are horrified at thought of the terrible things that might possibly happen as a result of some guy in a third world country making do with what he has and repairing an expensive or hard to find part. I swear, if our knuckleheaded banksters and politicians manage to blow the world up one of these days, it will be the barefoot mechanics of the third world that pick up the pieces and put it back together.
@@haroldmedalen6757 You have no idea how right you are. I have a milling machine of the German company Biernatzki, this year it turned more than 80 years old. And this is quite a working and accurate machine, which I completely disassembled and repaired with my own hands. And this company no longer exists. Such a rarity from the past.
@somebody else Both the gear on my shaper and the one on the lathe are done with the row of studs alone. The studs very nearly overlap and it looks like they were hand filed to the proper profile. The work is very finely done. It is possible that they were both done by the same person, as both machines have been in our somewhat isolated town for many years. I haven't found anyone who knows anything about the history of the repairs. I expect they were done back in the days when we had one steamship a week, not daily air service like today. If a part was damaged or failed and you needed the machine, you would have had to figure out how to fix it and keep it going however you were able. I think this guy's repair brazing over the studs, then cutting the teeth to shape with the tool in the lathe is probably a more durable repair by far than the studs alone, but I know I could run my shaper all day without any problems from the repaired gear. (Knock on wood!)
In my trade we had bronze rod high strength nickel alloy that I use to braze tungsten teeth to 1 metre cutting wheels . These rods are recommended by the manufacturer to repair or replace missing teeth on gears and also for high strength brazing .
Congratulations for that job,I remmenber when I was the techinical school,I wached the instructor, maked a job liked this.Greeting from Uruguay 🇺🇾🇺🇾
Brate svaka ti čast!!! Odgledao sam sve od početka do kraja! Ja bi otišao na otpad da nadjem drugi deo
We did this at TAFE (technical college) during my apprenticeship and it's called "pegging".
I had to do it in an emergency situation at work once to keep production going.
We also made a whole spur gear from scratch at TAFE - turned the blank on the lathe then cut the teeth on the milling machine using the indexing head.
This is economically advantageous in countries where the work of a locksmith costs $ 10 for a 12-hour working day, and CNC machines have not even been seen in pictures.
@canreplace в точку! Элемент путинской стабильности, как наследницы брежневского застоя.
Greate work and Nice to see👍
شكراااا طريقة لا تخطر على بال احد....طريقة ذكية جدا احسنتم استاذي
Интересный способ, как я понял - шестерня из чугуна и поэтому не наплавлял элекстродами, глядя на "износ" зубьев можно сказать что это не нагруженная(об этом говорит и то из чего она сделана) шестерня а сломались из за чп какого-нить. Бронза/латунь канешь не настолько прочна и поэтому вставлены болты для усиления, зато она лучше скользит в отличии от сыромятины металлической. Думаю шанс что она походит есть, способу быть.
Временное решение для того чтобы оборудование не простаивало пока придет нормальная деталь.
Absolutely brilliant as a "field repair" which was driven by necessity. Faced with the circumstances of what he had before which was "totally fuck8d-up" he now has something which, with a bit of tweeking with a set of Swiss files and engineer's "marking blue", enables him to use the machine. Is the lathe going to be as good as new, obviously not, but with careful usage he can now do things with it that in it's previous state was impossible. Necessity is always the mother of invention. Greetings from the UK !.
Very ingenious to use the lathe as a shaper!
Brilliant solution!
Thank you for the tip, you just made me subscribe!
With all the safety regulations we have to observe here in the states...I LOVE how this machinist is sitting there cross-legged in shorts welding this gear up! Just doing what he has to.
yes you office workers have a weird fetish about seeing blue collar people get hurt on the job
Yep, that’s the way the Master Machinist I apprenticed under taught me. Turn the carriage of the lathe onto a shaper with a boring bar and a form tool. Waaay quicker than having a new gear made.
Did you know that not every place on the planet is under the same economic pressures as conditions as you?
@@lost4468yt I'm not sure what you are trying to say the original comment was just describing the process in the video more or less saying the master machinist he was an apprentice for taught him the same method to save money instead of having to have a whole new gear made
Needing a machine up and running faster than the days to weeks it will take to get a new part in isn't that high pressure. On a decades old machine it might be the only option.
@@6181green I thought they were being sarcastic.
Good work by qualified worker👍👍
You're a genius at what you do
Для тех,кто не понял зачем это всё,должен помнить,что обломанные зубья шестерни из литья (чугуна),гараздо слабее чем болты из сырца и наплавленной бронзы....
Да ты гонишь, так это времянка, пока новую не сделали 😂
Boa tarde, gostei da ideia, mas você poderia soldar com aço 1045, aí ficaria perfeito.
Um grande abraço!
Cast iron is very hard to weld
Concordo com vc, e o primeiro dente saio fino e desalinhado, da pra perceber que a outra engrengem da um pequeno tranco, não vai dura muito
So simple and so brilliant. Bravo.
Cu prezoane implantate , o sudare corespunzătoare și o mortezare corectă , roata dințată agrenează din nou , Felicitări!
so many experts here go create your own channel and show the right way to do it.
The right way is to destroy it and make a completely new one. But respect, he fixed it with some basic tools, but it won't live long.
@@schelli3430 o
why would anyone waste time to do that?
This is the poor way 👌🏼...
Красиво сделано. Сколько читал об этом методе, и впервые увидел. Респект!
Интересно латунь износится быстрее чем чугун этот.
Видимо что-то попало в механизм и зубы оторвало
Как говорится на продажу. Себе так не станут делать. Один зуб так ещё можно сделать, чтобы был перехлёст с живыми зубьями, а так при нагрузке они быстро выйдеут из строя. Но это не точно 😉
@@user-nx8tf7ci6u почитайте ремонтные работы в сельхозтехнике. Новая чугунная или стальная шестерни не всем доступны. Сейчас в серую такая шестерня обойдется в 5-6к рублей, официально даже представить страшно.
@@_MadFox Какая разница, сколько стоит эта шестерня. Есть механизм, и ему не объясниш, что денег нету. Ремонтные зубъя, сильно хуже основных. Они ослабили колесо сверлением, металл напайки, скорее всего, мягче, чем металл на зубъях. Ну вот и представте что будет. Так вообще не стот делать, если ты не на обитаемом очтрове и вокруг зомби апокалипсис, и у тебя сварочник сломался.
@@MrMad-lp7in теория, это, конечно, хорошо. Но вот почему-то мне шестерни заказывают в Краснрдарский край из Читы, из Оренбурга... Это подходит под локальный апокалипсис?
Nice work!
First few minutes I wasn't sure where did this video came from.
And then I saw the bare feet holding the electrodes and it all got clear.
Very impressive! Thanks for sharing 👍.
И долго такая латунная заплатка прослужит ? А электросварки вообще нет, чтоб то же самое но нормально сделать ?
Нельзя нормально, отзывов мало будет. В целом просто бред конечно.
Мне тоже кажется что всё это сизифов труд. Для большей эпичности зубья надо было выпиливать надфилем.
Электросварка невозможна так как это по видимому чугун, при сварке место сварки закалится и зубья невозможно нарезать. Он все сделал правильно. Имейте в виду что это ж не завод и технологические возможности ограничены. Но раньше и ваши отцы так делали, просто вы отупели от деидустриализации. Сидите за компами и даже сверла заточить не умеете.
@@weldermusk8860 Плюсую под каждым словом.
Для себя отметил, что только русскоязычные отметились своей "невъебенной продвинутостью" и критикой.
Ска, да посмотрели бы как в России что "умельцы" сотворяют с новой техникой и гробят её, а уж про "реставрацию" чего-то вообще промолчим. Хотя, да - не все жопорукие, но дохуя и больше.
Тут люди со скромными ресурсами и возможностями и хоть как-то выходят из положения, но обязательно находятся те, кому нужно всё обосрать в силу своей ограниченности и тупизма.
Да, это чугуний и чел всё правильно сделал, как смог. Зубья притрутся, а пока сотрутся или сломаются либо новое успеют заказать, либо повторят потом процесс; факт в другом - работа механизма не останавливается надолго, люди дорожат работой и временем простоя.
weld it up with cast rods steel and cast don,t mix that well !And if you brase it you should heat the whole piece up and keep it heated .
Its a lathe part, so a slow speed and low torque application. I think it will hold well.
There are the bolts that hold the teeth very well. Its an excellent fix ,these teeth are now stonger than the others.
Excellent work...very creative. Thank you
That bull gear looks like it's about done, it looked like it had several other teeth repaired already. One positive thing with the way you did that and having it mesh with the harder gear the softer metal will work its teeth in overtime using the squish Factor. I never thought about using my lathe as a shaper. Thanks, I learned something new. From Virginia USA
You need to have the exact same shape on every teeth, there was too much load on them because the ones that were repaired before got the wrong shape. So now another 3 gonna be broken and again right next to the teeths that was just repaired... and how exatly different metal in something that needs to have every teeth identical is a beneficial factor?!
@Biały if you are wondering I was referring to imperfect duplication of the teeth using brass would allow them to wear into the steel teeth on the other gear. That is what I was referring to.
Pretty impressive, how long it lasts remains to be seen.
The gear or the repair? The teeths gonna last because the shape of the new teeths is wrong so the new teeths will be underloaded, the teeths right next to it gonna breake because they gonna be overloaded just like it broke before as you can see previously repaired teeths right next to it.
Necessity is the Mother of Invention.
Clever repair....my first boss in the machine shop once did this kind or repair with a shaper....cut a dovetail in the gear then shrank fit a plug, then formed the teeth as you have done.
Excellent repair mate well done 😁😁🤘🤘
Vai servir bem
Very good repair
Amazing work! 👍🏻
Really great job,I have done something similar but I like your way more, and the result was awesome, really well done
These guys are masters of repair. In the West this part would have been replaced most likely with a new one.
Labor costs in the West make such a repair unaffordable. This is assuming they can find workers who are skilled in this kind of work.
Maybe replacing whole gear is also more bulletproof? If this part will fail again, additional cost of replacing gear in machine will sum up
LOL! And their "repair" will last about 3 weeks and break again! Oh, us terrible Westerners! LOL!!!
I'd love to see you install this in a machine. Best case it jams, worst case it bends the shaft or splits the casting
The gears don't exactly ride on each other like he showed.... There is a small gap between the crest/crown of one thread and the root of the other....
The way he machined it , I don't see why it won't work.... This is in a place where they have to reuse/rebuild/repurpose just about everything..... I think he did an excellent job on the repair..... Depending on the quality of the brazing rod he used , I don't see why it wouldn't last a long time. The gears are cast iron. Not the strongest metal.....
The gears are rough and ready - including the wheel he was testing it on. In a poor country a wheel is better than no wheel and if it is running at low speed ( and it will have to be ) it may last a little while - he can always tweak it if it doesn't and there is some give in the brazing rod material anyway. Last resort he fixes it again. Don't be so negative.
@@we-are-electric1445 When he test rolls the gears against each other it’s clearly visible that the repaired patch has too much material. The gear bumps up and down over the brazing. When installed onto axles with a fixed and rigid center distance there will be interference there which causes jamming or other damage depending on drive power.
If he built a test jig with axles at the correct distance then he would be able to see this mistake and correct with his grinder.
Tooth form will be not even close to correct by eye to irregular wear is to be expected.
You are right in saying a wheel is better than no wheel. But swapping out shitty wheels every two weeks is not a solution.
Engineering knowledge is available for free, with that much better results can be achieved with similar equipment.
@@user-tw9io9nz2m So go and learn some engineering knowledge before making comments on something you have no knowledge of. Machining the gear on a his lathe is far more accurate than a grinder.
@@davidcraemer8227 so you’re telling me that this man can produce a better gear by indexing gear teeth with his eyeballs compared to having a test jig, seeing where the high spots interfere and gradually removing those with some patience?
The gear teeth may be the correct depth if he compared it to an original tooth on the gear before slotting but I still have my doubts about the tooth form and spacing of the teeth with literally no way to index.
Look closely and you can see the gear moving while he is cutting his first slot.
wow that is a clever idea for the repair. Thank you for sharing.
awsome, what these guys did! Such skills are unique...
For the shaping of the teeth, it will be very worth your time to deal with the slop in the toolpost, topslide, and however you had the gear fastened to the chuck. The part moved several times, the boring bar was pushed away from the gear way more than it should have been, and the topslide rocking on the carriage made me watch several times because I couldn't believe it was moving that much.
The way you're going about that repair is perfectly fine, and a nice job on the brazing. But, you'll get much better results if you can fix the rigidity of the setup.
b;ah blah blah.
@@CM-xr9oq - So useful! Do you have any other wisdom to share?
@@somebodyelse6673 his weapon is an ass and a puddle to blow bubbles😁
This guy is in a poor third world country and probably hasn't shoes on his feet. He's done very well considering the circumstances 👏
@@MsRustynuts India is hardly third world. In fact, your medication is probably produced there and the have a nuclear weapons program, ICBMs, huge industry and a vast infrastructure. You act as if he's in some African shithole...
this begs the question: why did the gear break in the first place? If the cast iron gear broke, then how long will braze last?
The answer is in the video and it is very visible, next to the broken teath you have teaths that also have bronze in them and on top of that the shape of this teeths are different=the load on teeths is not distributed properly...
maybe it was allready repaired
with brass solder
you just have to put on a new layer after every couple of turns ;)
Brilliant idea and craftsmanship there, I do like the threaded bolt idea for strength tho.👍
Amazing metal working!