ฝัง
- เผยแพร่เมื่อ 9 มิ.ย. 2024
- A bunch of side jobs cant hold me back from reassembling the gearbox with new shop made plasma nitrided gears. This video has it all, turning on the Boley lathe, milling on the Maho 400E CNC, T&C grinding on the Clarkson MK 1, TIG welding...
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The switch break out boards I used:
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USA link - amzn.to/3R5QaMP
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00:00 - Intro
00:14 - What happened to the gearbox?
01:41 - Mail time
01:55 - By-catch :)
02:58 - Side job #1 - Polish bearing journal
04:24 - Side job #2 - making the inter-stage bushing
10:50 - Side job #3 - Woodruff keys.
14:33 - Side job #4 - shimming the hacksaw
17:15 - Damaged tool #1
18:16 - Side job #5 - grinding drive dogs
21:18 - Gearbox reassembly
23:31 - Partial disassembly #1
23:42 - Side Job #6 - modify puller
25:28 - Side job #7 - more Woodruff keys
27:08 - Unscheduled disassembly #2
28:19 - Unplanned disassembly #3
28:32 - Damaged tool #2
29:16 - In between tidy up
30:18 - Side job #8 - getting bearings pressed off.
31:36 - Side job #9 - gasket making
39:59 - Test the gearbox
43:50 - Killed a saw blade.
44:05 - Damaged tool #3
44:29 - Side job #10
44:41 - www.docsmachine.com
53:04 - TIG welding the handle together - วิทยาศาสตร์และเทคโนโลยี
I am Emil , But I didn’t do near as much then the guy who made the gears . So special thanks for Him .
I really appreciate your generosity in helping me out there Emil. Thanks.
Still fantastic work :)
In the world where I work, it is a team win. Thank you for sharing your skills.
You’re the man Emil!!!
Good stuff Emil.
1k thx to Luke and 1k thx to Emil(?) ... 👍👍
Thanks Patrick.
Thank you Luke and Emil. Your incredibly generous contributions help generate the best 5 part trilogy worth cheering for. It was epic. 👍👍😎👍👍
Thanks for the kind feedback Joel.
Thank you for helping Emil and Luke
Thanks for that.
Wait, this is an hour long epic! I got to 17 minutes and started wondering why the show hadn't ended. Nice, and thanks for a great start to Sunday!
Thanks Vince. It was a bit of a mission to get this done. I didn't want to leave the gearbox half done.
It's good to have friends like Luke and Emil! Thanks guy's!
Sure is.
Very happy we got a little movie this week! An hour Long episode is always a treat. Happy to see the gearbox back in action!
Thanks for your kind feedback.
Thanks Emil and anyone else involved in the generosity
Nice one Steve.
Doc Nickel is a legend. I truly love watching the two of you rebuild old machines and aspire to do the same some day when I have the room to acquire boat anchors.
Back in the day, almost twenty years ago, I got a sweet job at a machine shop because the owner knew of me from my participation on Doc's forum. I learned most of what I know about mechanical design and how to build world class parts from that guy, easily 20x more practical knowledge than I learned in college studying mechanical engineering.
Hi Paul. Yeah, he is a champ. Sent me that drawing within 12H.
It's never acknowledged enough, but the amount of work and time necessary to make good video like this is Significant. Thank you for sharing!
Thanks for noticing. This one really was a bear to edit. I ran out of time to add music, which about half the viewers will be thankful for :)
The second launch of Starship was amazing. I think we forget just how big it really is. It looks like it came really close to getting into orbit.
Yeah, Iitwas amazing that the hot staging worked. Cranking three Raptors a small distance from a LOX tank... what could possibly go wrong :)
Thanks to Emil and Luke for their generous help. It was quite a long video, but definitely worth watching all of it. We all do stuff but not always finish on time. The way you looked at the video made me worry about you. You looked exhausted. You know what happens when you play with tools when you are exhausted. So please rest from time to time. I'm just saying. Take care, and thanks for the effort to put all things together and share them with us.
That one little bit was shot at midnight last saturday, about the time I realised I would need help pressing off the second bearing, and realising that I would not get finished with a video by sunday. Once i accepted that, the Px was off (for a week :)
I learn so much useful stuff from your videos. Today's nugget ( 7:06) confirms something I've suspected about my plain bearing lathe (SBL 9A), the spindle bearings deflate when static and inflate when rotating. This has been particularly noticeable when truing a job in the FJC. Thanks!!
I saw a scientific video on hydrostatic bearings, and you really see how the ride up to center. It has been about eight years since I scraped in the front bearing on the Boley, so it may also be a wear issue.
What a video! Our hero faces trials and adversity at every turn, but with the help of two kindhearted peers and a wise man, the action and drama plays out to our hero's advantage. And in the end we all learned a few things :)
What a ride.
Thanks for your kind summary :)
The plastic drafting board thingy, brings back memories for the late eighths early nineties . Simpler times.
Thanks for the video
Hi Steven, yeah, a cool design.
A press is what really separates us from the animals
Yeah, that and chamfers.
Good thing to wake up to, this gearbox finale! I’ll get some coffee and dive in. ☕️
Hi Doric, Turned into an Epic. :)
@@RotarySMP Wow, that was a three-cup epic! It had me Cleco’d to my seat the whole time. 😄 Too much to unpack the lot in a quick post, so I’ll say a hearty thanks to both Luke and Emil for their contributions. Well done, gents! 👍
@@624Dudley Glad you enjoyed that one. Was a bear to edit. I didn't get to music. About half the viewers would be thankful for that :)
3 things, big thanks to Luke and Emil. 👍2: Your bench was in the same state as mine gets when I work on a project, so don't feel bad about that and 3: Making gaskets is a dying art I think, when I was a young fella going to work with my father in the school holidays and even early in my apprenticeship, we used to make heaps of gaskets and then that all seemed to stop. 😒
I thought making the gaskets was the easiest part of this whole project :)
@@RotarySMP With all the dramas you had, I guess you're right 👍
@@MyMiniHomeWorkshop :)
I still have one of those Rotring drawing boards. It was a real innovation back in the day, just before CAD took away it's dignity.
Hi Mark,
My Dad had one when I was a kid, and I used it right through 4 years of tech drawing at high school.
I bought this one used out of nostalgia about a decade ago.
Mmmm, Blue Hylomar, Wigans best; courtesy of Rolls Royce.
And well done to Luke and Emil, I think that is one of the best things about the TH-cam machinest channels, the fact that people help one another out so much. Matty made up a gear for Max at Swan Valley for instance.
Thanks Bill. I agree. The community support with knowledge and help is fantastic.
Luke and Emil are rock stars!
Thanks Joel, they sure are.
Great job Mr SMP. Loved the video. The band saw looks awesome. I was shouting at the screen when you were using that low tooth count saw blade on the thin bit of steel, sorry you didn't hear me, I will shout louder next time. I also shouted STOP! when the part titled in the mill vice while drilling. Luckily you heard me that time. Thank you to Luke and Emil of course, they did a wonderful job with the gears. - Heather
Hi Heather. Yeah, not my best choices either of those decisions :(
That blade came with the saw when I got it 10 years ago. I need to cut out the bit with the removed teeth, and see if the blade is still longer enough to mount. The DoAll does have a pretty decent range of belt length.
Made me giggle when you went all Douglas Adams (RIP), on the 5 part trilogy
The save he was working on a sixth part when he decided to spend some time dead for tax purposes. :)
Working with 1/10000" and 1/100mm at the same time is next level
It works so well, I can design Mars landers for you :)
Congratulations on getting that repair done. Most people would never actually get around to crossing that sort of repair off the todo list. And, what a relief that the static leak test passed on the first try.
Thanks. I got lucky on that one. Hylomar is a very good sealant.
After so much effort and so many years of putting it off to now, finally, have it working. We all feel the joy.
Just needs a shiny new coat of paint.
It would be kind of cool to restore it , but would be a ton of work. There are a lot of extra holes which would need plugging etc.
That was an awesome episode, thanks a lot! I wonder if the gear was jumping out a lot before already and that wore down the teeth you needed to regrind. Luke and Emil, you are legends. 🙂
Hi Michael, I think that is quite likely. The gearbox was really worn out when I disassembled it.
Thank you Emil, thank you luke! all of us appreciate what you`ve done.
Thanks for your kind comment.
Thanks Emil(?) and Luke!! What a beast (in the best way possible) of a video, and what a journey! This video felt like the best story time when u where a kid! Not wanting it to end, but when did, pure satisfaction! Thanks for sharing!
Thanks Nick. I still have to tweak that shifter set up, but am really glad the gearbox is now in and usable.
Thanks Emil!
Thanks for commenting.
Thanks Luke and Emil. Well done both of you.
Good one JC, Thanks.
Thank you, Emil!
Thanks for commenting.
A prefect length video to watch while thoroughly cleaning and regreasing a new 3-jaw chuck. Thanks to Luke and Emil for their generosity. I’ve really enjoyed this series.
Thanks for the feedback James. Hope that chuck turned out well.
Awesome video !! Enjoyed the full journey....the path is rarely a straight line. Thanks for including the potholes, bumps and curves along the way.
ATB......
Thanks for your kind feedback.
Great video, but you should replace the battery in your micrometer. They can in my experience be less accurate when the battery gets low.
Thanks for the tip. I got new batteries for the caliper, but forgot to get the one for the mic.
Nice going Emil! I'm looking forward to the secret sixth part where you build a shop made press! Also love the shout out for Doc. The whiteboard is great.
Thanks for your feedback.
In my apprenticeship i worked on old cars. There i learned a trick for quickly making new gaskets. if you hold the paper in place over the part and take a small hammer and knock on all of the edges gently, it makes quite a nice template to cut out. Actually it almost cuts right threw. Same works with a small key file instead of a hammer. Or even just use a dirty finger to go around the edges :) As always, thanks for your great videos!
Thanks for the tip Niklas.
Emil & Luke, nitride-hardened-steely-eyed machining folks! Thank you!
Thanks for that.
Ok, now that I watched it all, more comments:
- stop putting yourself down, young man! That was a most enjoyable long video and needed not a bit of patience! (but the stats at the end were a great addition!)
- so pleased the gearbox worked. Gut Ding muss Weile haben, or thereabouts!
- you have an amazing community! ToT sent me here, you sent me on to … ow, forgot his name, lovely guy who does such great work from scrap, and makes electric Jeep. Anyway, with Luke and Emil, all the LinuxCNC folks etc. in your orbit, I feel like I am allowed to glimpse a bit of the table of the chiefs. Very satisfying! :0)
- your parting tool is f****d! Ether that, or that steel was special secret service stuff. The scary deflection of the spindle made me wince each time!
- ummm, should the grinding machine be bolted down perhaps? It moved when you pressed material at the wheel….
Great Sunday morning - thank you!
@@mumblbeebee6546 Thanks for the kind words. I was pretty frustrated to screw up the bearings (twice) and also to still have the shifter not working yet. At least making another excentric bit is not a big job.
It has been about 8 years since I scrapped in the Boley spindle bearing, so I wonder if the clearance hasn't worn excessive.
Jeremy makes things. That is my favourite channel. He is brilliant.
@@RotarySMP Oh, I see… in that case I profusely apologise to your parting tool for slandering it!
Wow! We have all been there, sucked down the rabbit hole of confounding contraptions. Good on you for sticking it out.
Thanks for the support. I am still trying to get that shifter tuned.
Emil did more for you than you may know.
That indexable mill body is an interesting unit if it is what I think it is. If it’s a high feed mill, you should do an entire episode on what you can do with it on your mill. I use this almost exclusively for my steel roughing operations. They are fantastic.
Thanks for the feedback on that Craig. I need to make up a shank for it.
Big thanks to Luke & Emil for the support pushing you to the finish-line.
Thanks for commenting Rob.
Hi Emil thaks for helping Mark! Great progress in restoring the saw back to its original state
Thanks for that comment of support Steve.
Thanks! Always entertaining. And thanks to Emil and Luke.
Appreciate the comment. Thanks.
thank you from all of us
Appreciate you commenting support for Emil and Luke.
Side quests are worth doing. Respect man
Thanks for watching.
Thanks Emil! Also hooray for a complete gearbox!
Thanks for your support.
Emil, thank you for being a nice human being !
😃
Thanks Toma.
Wow, What a generous community.......
They really are.
Thanks to Emil and again to Luke. Only 9 side jobs if I remember correctly. Sounds about right, maybe a little low for me… 😂
Yeah, they quickly add up. I could have broken down the parts of the shifter drive into five more :)
A big thanks to those that helped this project/repair.
Thanks for commenting Ken.
Well it was fun making the gears and even better watching the rebuild. Just glad to see the saw back together
I really appreciate that you made two sets when you had your indexing set up. Sorry I ruined the first set.
@@RotarySMPwell they will still make good wall art :)
@@LCalleja Maybe I can use them for some other project, where I could reduce the shaft diameters to the next bearing down?
@@RotarySMP That sounds like a side project!
@@LCalleja Always :)
I just found this channel, so far I am loving it. Very well put together, editing, content. 👍🏻👍🏻
Welcome Jason,
Thanks for your kind feedback,
Mark
Absolutely worth the effor. I reallly enjoyed watching this epic project 👍😃
Thanks Antony. I am glad to be able to cut steel with this machine (once the replacement blade arrives.)
Best part of Sundays! Awesome job and thanks Luke and Emil! 💪
Thanks for your kind feedback.
Brilliant video. Luke and Emil, champions.
They really are.
Thanks Luke, Thanks Emil!
Thanks for commenting.
A true pleasure as always!
Thanks Alex.
Epic!
Well done Luke, Emil, and Mark.
Thanks for the kind feedback.
Nice job on the video, as always. There's an impressive amount of work here with all the reverse engineering and repairs. Seeing all the mechanical complexity involved in changing speeds is giving me even more appreciation for VFDs!
Thanks for watching it. The nice thing about a gearbox is that torque multiplication. I am really happy to have received the assistance to get this working again.
Thank you Luke and Emil
Thanks for commenting.
Thank you Emil & Luke👍
Thanks for your comment.
13:35, that's quite a radial movement, can't wait for lathe bearings rebuild video :)
I scraped the bearings back in about 8 years ago, and it looks like it is due again. I am more likely to sell the Boley :)
@@RotarySMP You know I was just thinking about it :), how do I contact you?
@@NskLabs There is an email link on the channel "about" tab.
I admire your persistence.
Thanks Carl.
Wow fantastic project...always love to see manual drafting from a fellow tuber as well
Glad you enjoyed that Craig. Thanks for the kind feedback.
You made my Sunday again.
Thanks for watching it Willem.
The challenge of imperial mesurements and French writings in Austria...
But still, it's a nice puzzle.
Hi Michel, I have a pretty random mix of metric and imperial stuff as NZ only switch in 1970, so my Dad always used imperial, I learned Metric at school, but then was back to imperial in my aircraft mech apprenticeship.
Thanks EMIL
Thanks for commenting.
46:24 Nicht vergessen, die Leitspindel reichlich zu schmieren ;)
Another moment Rapido/Lente. German, French, Spanish machines. Multinational workshop - I like that a lot. Also I appreciate you using both: imperial AND metric (even though I am a metric fanboy bcs of superiority). Your fanbase is quite something one would assume. Thanks to Emil and the gear cutting guy!? :)
Yeah, I tend to oil my machines a lot. Thanks for the input.
Great video. Thanks to Emil and Luke.
Also thanks for the bit where you talk about the plain bearing on the Boley- I've just recently got my first lathe. It has plain bearings, and indicating stuff in is driving me bananas. Ill try warming it up next time and see if it helps
I suspect it is time my spindle bearings need scraping in again. I last did them about 8 years ago.
@@RotarySMP There's an adjustment on mine to take up the slop with some sort of tapered doodad, but I've been loath to mess with it until I understand what I'm doing a bit better. Still on the fun steep bit of the learning curve where accuracy is notional anyway
using a hss steel blank for polishing with a sand paper is very smart, I need to remember that
Best source of flat ground stock in my shop.
An early Christmas gift !!
You are one lucky SoB !!🤣😅
It is nice that Emil and Luke helped me out like that.
Well done. Although some loose ends to still tie off, an ambitious undertaking for a single video. Congratulations on getting your shifting back.
Yeah, at least the gearbox is working. I'll take some time measuring exactly what eccentricity I need, and remake that part.
Epic both in effort and videography. Thanks for producing this.
My thought, which will proabably get me sent to the bottom of the class in this company: for the gubbins (technical term) at the end of the gear-shifter it may be easier to 3D print rather than machine. It would be easy to reprint with different dimensions if needed (though basically impossible to re-work without reprinting).
Thanks for your kind feedback Iain.
There is a fair bit of load on that gubbins (tm) :) so I doubt it would work in plastic. Also plastics are not really stiff enough for that application.
Great video buddy!!! It was worth the wait for sure!
Glad you enjoyed it. Thanks.
Thanks for documenting this.
Thanks for your kind feedback.
A-Team Luke and Emil !!! Merry Christmas!
Top guys.
Love the long format!
This one was a monster :)
Awesome video! I realy had a good laugh at you 5 part trilogy! 😂 your videos always make my sundays and make me wanna go to the shop myselfe. Shout out to Luke and Emil! 💪
Thanks Simon :)
Those parts look cool thanks Emil 😀
Thanks for your comment Julia.
Well done to you all. 👍
Thanks Paul.
Thank you Luke and Emil! Your variator belt might be worn, they wear on the edges in use, when they get to be too narrow it allows the pulleys to run out of range.
Good point. They bounce around a lot in use, and have probably taken a set as well.
@@RotarySMP It also just dawned on me, that my Big DoAll has a 3-speed gearbox. It also has a mechanical lockout to prevent shifting gears unless the variator is in it's lowest speed setting. I wonder if your saw had similar and the previous owner disabled that feature? That could explain the damage to the jaw coupling inside?
Cheers Emil
Thanks for watching.
Great video. Thanks for all the hard work.
Thanks for watching it.
I think big plain screws are still a good idea in certain situations. They do require more skill from the operator and a tightly fitting driver. Plain screws seem stupid until you need to make a screw and realize your rotary broach is still in kit form and will add days to your project. Here in the USA, there's been a 50 year glut of screw-driver-objects on the market so plain screws have fallen out of favor. But the wooden-boat guys still use them. That trade seems to attract craftsmen rather than operators...
Good points. And they do look cool.
Hi neffk , as a Canadian, I feel sad for the rest of the world that has to deal with the horror of slot or phillips screws when they could have
the obvoiusly superior robertson (square) head screw 😁
Having said that , I spent a lot of time is industrial electrical control boxes where screws that combine phillips, square,or torx with a slot are
are by far the best solution . the inner screw for run it in and out and the slot to torque it down or loosen.
Thanks emill ❤
Thanks for commenting Dan.
Grate video as always! liked the long format and nice to see the DoAll back in working order.
Hi Luke, You gearset seems to fit and work perfectly. I just need to fine tune the shifter set up a bit, but you rescued a nice old saw there with you gears. Thanks again.
Love the long videos
This one was a bear to edit.
Hurray!
Thanks Tom.
ecellent journey to almost finished band saw. I love your channel!
I am liitle but confused about length unit - in one video, you use both metric and imperial unit.
Be kind. Use metric.
#3 fan
Working in aviation you have a lot of imperial, and I received imperial measuring from my Dad, so I just grab whatever is best for the job at hand :)
genius way to make woodruff keys. Now I can save a 40 min trip to ACE by spending an hour making them. (not dealing with ace employees makes it a good deal)
At least you have Ace. Getting inch Woodruff keys here in Euope is a much bigger mission :)
oh how i looked for the emergency stop button on my keyboard when that drill started pushing the thing out of the jaws
That was not one of my better set ups. I had cantilevered it out for the end rounding to avoid cutting my vise, but didn't really consider the drills force line.
Thanks again mark
Thanks Jonathon. Glad you liked it.
I think another problem with the eccentric is that the shifter ring has worn, and has been ground flat twice. Each of those means it needs to move a bit farther to engage.
Could be. There is no obvious deep wear on the faces, but I suspect my grind on the drive dogs migh not have enough angle.
Another great video
Thanks for your kind words Steve.
Awesome video, I really love the longer lenght ones. Really like to come by and visit you some time and say hello, shouldn't take long, quick trip on the bike from bavaria to austria.
Thanks for watching it. It was a lot more than I usually produce, and a bit of a bear to edit. I couldn't do videos this length regularly.
You better get biking before the snow comes :)
Lego, the original gateway drug.
When I was a kid, lego was just a box of parts, and you used your own imagination. They sure hit jackpot once they switched to making kits specific models.
Great work Sir, great work! You had a little jster1963 luck too ;-)
Hi Jasper. I'll take all the luck I can get :)
Great video. This has been quite an involved fix. Thanks for sharing this with us
Yeah, it really has been a lot more work than expected.
your headstock bearings are lose !
if you watch when you try to part off (minute 15) you see the chuck pushing away.
cheers ben.
I last scraped them in about 8 years ago, and it was the first time I have ever scraped a plain bearing, so you are right. They are again due.
Thank you for WATCHINIG 😎
I had a bit of a panic attack when you started to cut thst steel with such a coarse bandsaw blade and such a low speed!
I use a 16 tpi blade and a lot more blade speed than that.
I need to work out how accurately that speed range chart fits with the really tooth speed. And I should have checked the real TPI.