Repairing a Broken Gear Part 2: Milling a new Gear Tooth
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- Опубликовано: 20 ноя 2013
- Milling and installing a new gear tooth in a dovetail slot in an old cast iron gear. In this video, you will get to see milling operations on my Wells Index Vertical Mill, Kearney and Trecker No. 2H Horizontal Mill, and Lodge and Shipley Model X Lathe.
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Joel Hunger
2014-11-27
I'm a database engineer by trade, but my dad was a machinery maintenance technician and my grandfather was a machinist. I've always been fascinated by machining, especially manual machining. I started watching Keith's videos, along with Adam Booth and Tony, and eventually decided to go ahead and acquire an old industrial mill and a lathe for my home shop, and learn to use them. No DROs, just old school dials and indicators. I love the pure analog experience of it. So many of the engineering principles of my professional work apply in this skill, but are more visible and tangible. I genuinely appreciate the willingness of my RUclips shop teachers to guide me in my new hobby.
Keith once again shows off his machining skills as well as his wonderful ability to convey the reasons why he is performing whatever process he's doing. I've spent 51 years as a time served engineer and I've still found this video inspiring, educational, and enjoyable. Thank you Keith.
Me and my 98 year old, ex tool and die man father give you a huge thumbs up!
I like very much when people answers to commentaries, even critics, Mr Rucker. And in mechanics there are several ways to do one only job. I believe it's for a museum, estetics prevail, and your work is clean. Good ols machines you have. Thanks
Hi Keith,
many greetings from good old Germany, my father, born 1933, got a tool maker and I should tell You you did a good job, make it easy to understand, by the improved special solutions he feels like a kind of Soulbrother,
Greetz, and THANKS, Linpotec
I really enjoyed watching the 2 parts on this tooth repair and it was very educational.
Keith. I want to commend you on your skills as a metalworker and I really enjoyed watching your video on this cogwheel. Unfortunately, true craftmanship like this is becoming rare, just like real blacksmithing. But i'm glad to see it isn't completely gone yet. Keep up the good work so I can enjoy more of your video's :)
Just wanted to let ya know that these two videos were really interesting to me! I run a large CNC lathe and a standard sized mill turn CNC machine daily at work and watching you repair machinery is indeed an art form to me.
***** That's awesome, kinda scary to think though that those guys actually had a job as machinists without having to know how to run manual machines. Luckily I can fumble my way through having to make something on a manual machine, it's not often that I do have to make something on one, but I can still do it. The shop I work in required that you know how to run both manual machines and Mazak Mazatrol to work in the CNC department.
Fantastic! A job that would make mere mortals shake in their boots executed brilliantly sir! A tip of the hat for sharing!
Job well done. I'm sure our industrial forefathers are tuning into this great series from somewhere, nodding with approval.
I'm curious as to which Silv number you used. I have fought tooth and nail trying to source the correct brazing rod for cast iron.
Thank you, good sir.
In a world where the phrase "beyond economical repair" is bandied about for jobs that really don't take that long or are that hard, it's a genuine pleasure to see a craftsman take the time and effort to restore a piece of history like this. Well done and thank you for sharing.
was with this process from the beginning. what a treat to witness a mechanic directing precision work.
my father learned to be a watch maker in Germany after WW2 WHEN HE WAS A JOURNEYMAN. He APPLIED at solex carburetor as a machinist. they called his bluff by handing him a plan for a carburetor and block of aluminium. needless to say he didn't get the job. I am a jeweler though. this stuff is great,thank you....
I really enjoyed this piece of work. Working with my heavy equipment and farm tractors make me appreciate guys like you. Great job all the way around. Yep, and I know about welding cast iron and it's always a gamble.
you're welcome. I could sit in that shop for hours to piddle and watch.
You are the best engine dentist at all!
Impressive work. Making a complete smaller gear and mating it to larger gear with a steel tooth would be the direction I would have gone.
I know nothing about milling or machining. But after watching your videos, I wish I'd become a machinists myself. I really like your attention to detail. Thank you for the videos and for sharing your wealth of knowledge.
Great job doing the minimal amount of setup for that piece of antiquity. Always enjoyed cutting gears on a Bridgeport which is a machine I would disassemble and rebuild as a maintainence machinist.
Would love to return to the trade but now work in wood at home.
How good to watch years of experience, condensed into minutes. If we do not continue to learn from these masters, we will lose their gifts forever.
Brazing is pretty good and traditional but there are sone great new welding methods that would safely make that a much stronger repair. I love your videos! If i ever get a lottery payoff or find a machine shop sell-off I’ll get to try more of those methods. At this point I’m a ‘farmer machinist’ but it works well with persistence and patience
Keith, I really enjoyed watching a true machinist/fabricator at work!
My dad was a machinist for more than 30 years and I did a little training in that area in and just after high school. I didn't stay in the trade and sometimes wish I would have. I think I would have enjoyed taking on the same kind of challenges you did so well!
Again,it was nice seeing a machinist at work. Thank you for posting.
Very nice work. Watching a true craftsman do his thing is better than any program on television!
Quite so. It's funny how we're supposedly eager to watch, say, cops doing their job in countless procedurals, but machinists - not so much? Well I for one enjoy watching this more than any NCIS...
Just wanted to thank you for sharing your knowledge and skills so freely with us.
A great deal of respect from me. Walking us thru step by step & explaining your choices & decisions etc = priceless in my book.
Hi Keith, A really good set of videos, and good to see the old machining skills are still used to save old bits of machinery. I Have a 1919 Economy 3 1/2 hp Stationary engine and had it shipped to the UK and that needs machining work as well, good to see the process of renewing a tooth. Great Job, like the steam train whistle as well :-)
Thanks!
A i can say is WOW im 62 a carpenter by trade. me dad was an industrial arts teacher. I learned alot from him you are really good, if you would have been one of my teachers i would have gone alot farther in life keep up the great work. you are really fun to watch, thank you
GREAT JOB! Your patients is commendable. The art of repair and rebuild is something that is long gone in todays throw away sociality.
Wow. You are an artist. Thanks for showing the whole process.
Edward Nikoliich And thank you for watching!
I really appreciate your ability to 'see' the finished part in a hunk of scrap cast iron.
Keith, that's very fine, quality work well done ! Your skills are rapidly disappearing from the industrial scene. You are worth you weight in Platinum Sir ! Many shops call themselves master machinist shops, just because they have a computer C & C machine. Well, that's great and also greatly needed nowadays, but we also need master machinists who possess the skills to know how to do this work strictly by hand. Custom repairs cannot be handled on the C & C Milling machine.
Mark Job You are so correct. CNC is the way to go for production work, but when it comes to making the one off piece or custom repair work, you have to be able to do it manually.
It's great to see someone else who doesn't "just go buy a new one" when something breaks. There is a certain satisfaction that comes from fixing something that was previously unusable. My teenage son is just starting to appreciate that feeling. Wonderful, informative videos.
Tim Green excellent comment I couldn't agree more. The satisfaction that arrives with a job well done has to be experienced to be appreciated and or understood.
Great presentation and excellent job Keith. Enjoyed watching your 2 part video. Your attention to measuring and setup is impressive, which reflects your superb tool-making, craftsmanship and machining skills. Thanks for this informative video and God bless you.
Just stumbled across these videos. Very nice machine work and great video editing.
The even better news is that now I have several more videos I get to watch, as I have now subscribed to your channel.
Oh, and as a resident of Georgia who has visited your museum, fantastic work there as well.
+Ron Icard Thanks Ron, come back sometime if you are in the area!
I think thats simply a brilliant solution! I work as a technologist in a gear factory, and i'd choose to remanufacture the whole gear. Was a joy to watch your vid!
I think one thing in Keith's favour for this repair is the amount of metal in the hub of the gear. Modern gears have less 'spare' material and making a complete new gear may have been the only sensible option.
Beautiful precision work!!!!! Restoring old technology is wonderful -- Bob
Thanks for taking the time to share all this with us. I for one enjoy watching this sort of thing immensely. Well, not just watching, but my tools are quite modest.
Thanks Keith, good job. I didn't know that could be done.
The best is the best you got it there Keith all in one shot 👍👌😎
Hi Keith: Excellent video on working with cast iron and milling out a gear tooth. Keep them coming.
I've never in my life seen this done before, both video's were very interesting, I enjoyed them very much. I would have welded the gear back up and reshaped it, but the reason I would do it that way is, I don't have a milling machine, or the knowledge to run it. I believe your way is the best. I have learned something tonight that will stick with me the rest of my life.
Thank you
Mark
***** With proper pre-heating and the correct rod, welding cast iron is no longer the daunting task it used to be. A 55Ni rod should work well in this application and would be machine-able.
Keith, you are truly a master of your craft. Amazing job.
Sorry but a true master would have silver soldered it in properly and not only on one side of the joint. @34:29
Very cool to see. Amazing to see machining without fancy computers. I am jealous.
It is the way machining has been done for many years. At least until all of the computers started taking over for people's brains....
i dont know why but i find this kind of work really satisfying
+michael ranasinghe Thank you - I do too!
Fantastic! I could watch craftsman like you all day.
all done having all kinds of fun , great job
Excellent work Keith. As a fellow machinist I would have squared the block of cast and not just the two opposite faces, then you would be 100% certain that the block would not "kick" in the vice
I did the same thing once in plastic. It was a gear from a fax machine. A notch was made with a saw and a piece of ABS sheet was epoxied in. The profile was cut by hand with small files. It's amazing how well this works.
If you have the stock laying around, it makes sense. Would get expensive fast if you had to order it in! I probably would have made the shaft and then the larger OD base out of plate, welded, then machined the plate true with the shaft, if I didn't have the stock on hand! Amazing repair, thank you for sharing! I just found your channel, and subscribed instantly. I usually watch Keith, Ox, and Abom, but you're up there with them now!
Unbelievable Joe nice to know their are still people that know what their doing
I am enjoying your video programs. Well made, informative and most pleasant. I learn something from each one and look very much forward to absorbing them all over time. Thanks for your fine efforts to share your work processes with us.
This is a kind of magic. That gear was destroyed!!
I really enjoyed watching this. You are indeed an accomplished machinist. OK so you do talk a lot but watching the work you are doing is well worth the wait. Of course when it took longer than I wanted it to I just hit the right arrow and got past it. Really nice work Keith!
+Jonathan O'Connor Thanks Jonathan. One of the things I try to do while I am working is do a bit of teaching rather than just do the work. Some people love it, some hate it, but that is my style and what I plan on continuing to do. Glad that you enjoyed!
Jonathan, you said it well. Those of us who are experienced repair machinists can fast forward to the "good stuff" but I feel it's great that he takes his time to explain to the novices. Better to have all the details for those who need them when modern technology allows us to speed up the video.
Fun to watch how other people solves the problem, Thumbs up!!
Great job Keith! Repair work, especially with castings, always presents some unique challenges.
You are a master! Nicely done. A great effort and a great video.
Love your editing. Quick and to the point. Talk when you m
need to talk.
Job well done by a skilled journeyman - thank you for sharing !!
Great video. Thanks for actually not editing out the problems.
I had an old garage door gear similar to that one which was cracked in half. Not being produced any more, I cut a new one out of 1" plate steel on a water jet. Worked great!
+larry munday On course teeth, cutting on a waterjet will actually do a very good job! I have seen that done a few times.
When digital technology inevitably fails us, these skills will be worth more than all the gold and silver.
I have the greatest respect for your work and the calls you make to getter done
Thank you for your time and expertise, I wish I lived closer to your neck of the woods, I would volunteer with the museum. Being retired without a task is not good. Anyway, thank you again, it's few and far between you find the Master of his Craft anymore. I hope young people will watch as this is an Lost Art of Skills. Maybe your RUclips will be Archived for a long time.
Wow great job on the gear tooth.
A very inventive repair, thank you for taking the time to film and share.
Good job , professional like you with this kind of of craftsmanship is very hard to find , the new generational of mechanics want to replace the part or the whole machine with a lot more inferior quality;
I am glad you sharing your knowlage to teach others
keep up the good work
***** Hope you don't mind me saying Keith but that's not strictly true. I work in Formula 1, yes there's a lot of state of the art tech going on, but we have several manual machines and they are used on a daily basis. Also all the apprentices that come through every year start on the manual machines first, they only go onto CNC in year 2/3.
Thank you for taking so much time to make an instructional video ..i really love seeing the skills how to make stuff on the milling machines..hope to see a lot more videos from you....keep up the good work..
Best regards from holland...
very good video as always, hope it holds up in service.
That was a lot of work! Great job!
so glad i found your channel, i just love how you do what you do, thanks so much for sharing your trade, you are a true master at what you do sir
I had no idea how that could have been repaired, just loved that, and well done too! , Thanks.
Exquisite repair Fred. Thanks for taking the time to make the videos and post them. Like your machining, they are very professionally done.
Try Keith
I enjoyed watching that repair. I wish I had the patience to do stuff like that. Excellent job sir.
Good thing you finally did the fly-cutter feed. Didn't make sense to be at first why you were relying on the shape of the bar in the vise. Not that I have as much experience as you... :D
Ive thoroughly enjoyed all of your videos! I really like your explanation of parts, pieces, tools and your redos! The tooth repair was awesome!
Thank You. You are just one of the greatest skillful machinists. I admired your great work
+Liem Duong Thank you!
Fascinating fella, a joy to watch
I am sure this will make a great repair Keith but I guess you simplified the cutting of the tooth by making it flat sided. In reality, of course, the sides of the tooth are of the form of an involute curve not flat. To avoid the complexity of creating the curved sided tooth, I agree with your methodology of making the tooth the way you did. Good job. Looking forward to seeing it all up-and-running.
Excellent craftsmanship my friend. That looks like a lot of fun.
Keith, I truly enjoyed watching this mini series. I hope to see this gear in action at some point. You've got a new subscriber.
Great job and very inspirational.Your kind are very few and far between.Keep up the good work.
Brilliant !!, nice to see somebody determined enough to resurrect the old machinery, if only you could show the repair to the Gent that originally cast the gear
Nice repair on that, always interesting to see manually machined repair works.
Your skill is phenomenal! The production of this video is amazing. Thanks for the information.
Stunning work Keith! You just got a subscriber. Thank you for taking the time and putting in so much effort to entertain us and teach us
Boy that takes me back, My first job. I always had to used an oven to control the heat on cast iron. We use to also stick in in a bucket of lime to slow down the heat dissipation. That's old school stuff that has been lost. The first horizontal mill I used had a Muncie 4 speed conversion used to drive it. I imagine it was belt before that. Cast will crack at the drop of a hat. It's very tricky. Remember temple sticks? :-)
Nicely done job, the dovetail root looks very strong!!
You taught me a few tricks, thank you sir and keep up the great work.
Enjoy watching your videos.
Amazing work Keith, love your channel!
Beautiful job!! Well done!! :D
and thats how a BOSS fixes a gear!!! nice!!
Beautiful work, sir.
+Charles Davidson Thank you sir!
I have that same horizontal mill holding down the corner of my shop. Don't have the shaping attachment though. Great video and thanks for sharing.
I am a new subscriber and enjoy your skills and comfortable style of talk. I also very much like the train whistles I hear from time to time. Very nostalgic. Thank you! Fred
Great job - great videos - truly enjoyed - thanks
You are an excellent craftsman. Greetings from Denmark
Your new tooth looks like it's of better quality than the rest of the gear, what with the pitting and generally rough surfaces from the sand casting manufacturing procedure.
Great Job Keith!
the same tecnic we use to fix broken clock gear! great job!
GREAT JOB, you sure are talented and provide good and clear instruction, that you for uploading !!!!
Thanks for you very informative videos Kyle. I enjoyed both :)