Your ingenuity and refusal to accept “can’t be done” shine as always. Some normal shop difficulties, but all overcome in style. All in a days work, so to speak. 🥂
I would recommend clearance hole on the top plate, and tap the bottom one. That will definitely get rid of the "weird" feeling in the transition between them 👍
Hi Michel ☺, looks like you'll have a working gear when it's finished, full mark's for making ,and adapting, as you go along, and that's what makes your video's more interesting, many thanks mate, stay safe, best wishe's to you and your's, Stuart UK.
Michel, instead of having to make up the proper thickness of packing for your shaper vise when the part can only be held on one side of the jaws, try using a relatively large diameter bolt & nut to quickly make a DIY machinist jack. Of course, you'd need a selection of bolts with different lengths. You could also use a coupling nut with the bolts or threaded rod.
To measure the diameter, use a caliper from the bore to outside diameter X 2 + the bore size gives you the outside diameter size, very interesting video thanks, from Coventry UK 🇬🇧.
Ahhh, single point gear cutting. I am familiar with this 😅. Noisy, takes forever, but it'll get the job done. Though I do not envy doing 125 teeth 🤣.... Switches to a real cutter 🤣. Good call! Cheers!
If you do not have a large caliper to measure large diameters, you can also use the micrometer dial on the cross feed. Simply bring the turning tool to the center, in this case the bolt, set the dial to zero and turn it back to the desired (or to be measured) large diameter. If the center is difficult to find, you can also take the starting size somewhere else, even the tailstock quilt. You can measure this with a regular caliper and add half the diameter. Not as accurate as a large caliper, but certainly more accurate than a ruler or tape measure!
G'day Rusti. Great idea bolting the 2 plates together. As the old saying goes, "where there's a will, there's a way". Not easy at times holding flat plate and machining it. Especially with the intermittent cutting that is hard on inserts. Cheers, Aaron.
Thanks Rusty, nice approach to making this gear. Using the steel you had and making a gear cutter. Nice work. Thanks for sharing and have a great weekend. 👍👍💯
I prefer to tap by hand as well. As you say you get better feel for how it is cutting. The gear is coming along nicely. It look's like it is taking a while, but if you cant source a gear then the only option you have is to make one.
Hi Michel. Outstanding project. Breaking taps is a given, no matter how hard you try not to. It’s that split second before they do when you realise it’s too late. 😮🥴😱😢 I so enjoyed seeing how you tackled cutting the gear. You never fail to surprise me. I look forward to seeing the new gear being successfully put to use. 👏👏👍😀
Great video Michel. I’m enjoying this one. It’s horrible when a tap breaks. I broke a tiny drill in a part recently. I was lucky that I could punch the broken bit through the hole. Can’t do that with a tap 😢 Cheers Nobby
Great video, love your sense of humour. Please tell me and the rest of the viewers where we can buy one of those tape measures that measure down to microns as I feel this would be a great accessory to my workshop.😂😂😂 Cheers keep up the marvelous work.
Just had to mill out a broken tap myself.. it was a close one too. I was most upset about the tap, it was one of the better ones in my collection. Glad it worked out good for ya. Greetings from Indianapolis Indiana 👋
My friend just did something similar where he put together three plates. He drilled holes in the two outer plates and welded through the holes to the center plate. seemed to work okay. Your method looks nicer than his 😁 Thanks for sharing Cheers
Awesome entertainment! Sometimes a walk around the local metal scrap yard can save hours of griding drilling and tapping... but not as much fun for us to watch. 😎 Re the measuring, I recently bought some cheap vernier calipers from Ebay and Temu, so I can have some "basher" calipers to leave laying around in tool trays etc. It's good to have them in arms reach and not need to get out the expensive ones. They were actually quite decent in terms of accuracy. For your gear you could have used a 200mm vernier, I got one for about $13.
Great video, thank you. Watching this today is pushing me to do something with my rotary table/dividing head. I've not used it yet. I never even set it up on the mill. Interestingly, I also watch Machining and Microwaves. I also have no idea what he is on about but love to hear the passion and watch the machining content.
Hi Michel. Excellent progress, great to see the shaper getting in on the action too. Seeing you make this gear out of two plates made me think for a moment that this would make a great anti-backlash gear, not that you need one of course!! Have a great weekend!!
I have a special pair of glasses for the workshop. With side protection in a case. Nice smaller machines. Interesting where you machines originated from?
Je n'ai pas d'outil pour mesurer des cercles aussi grands. Ce que je fais, c'est mesurer la circonférence et la diviser par pi. Tu seras surpris de la précision obtenue.
Hi Rustinox Good video as usual. I like your milling machine - Deckel? I have an Aceiira F3 and it looks as though your collets are similar to the W20 style, but longer. Good luck with the gear. John
This must be a first... using a tape measure on a machining video😆 Exciting, isnt it, cutting lots of teeth on a gear. Praying you dont miscount a mess it all up!
Your machine screws are adequate enough for the use this gear is going to see. If someone was doing this for a higher torque or heavier use, rivets would be a much stronger choice for low temperature fastening. Im not trying to denigrate your choice here. We all use what we have available in our shops. Im just making an observation that might help someone out there 😉👍
Well, what I would do and it is what I do, is to drill some holes close to, but inward of where the teeth will bottom out, on one plate about 10mm, 3/8” in diameter and weld the two plates together. A few holes closer to the center would be welded as well. He agrees that it’s the best way as well. Heavy rivets will work as well as long as they’re riveted properly, which is hard to do in a home shop in parts this heavy. With the screws (they’re not bolts), I would cut the ends a couple of mm short and thread one plate. After screwing them in as tightly as possibly, I would then spot weld, with the MiG welder, preferably, on the threaded end. That would also make for a tight, permanent connection.
@@Rustinox not to hijack the conversation, but i don't fully agree, you have a forge right? Heat up the rivets in the forge, drop them in the gear and knock them in
It’s funny. I find my self saying “ problem “ in best copy of Rustinox voice. Love the videos. Thanks. Best sense of humor in TH-cam
That's nice :) Thanks for your kind words.
Your ingenuity and refusal to accept “can’t be done” shine as always. Some normal shop difficulties, but all overcome in style. All in a days work, so to speak. 🥂
Just go for it.
Nice save with the busted tap, Michel. Every machinists worst nightmare.
a busted tap is everybodys nightmare even wood carvers
Indeed, it is.
One of these days I'm going to make myself a homemade edm machine for removing broken taps!
Have a nice weekend.
Go for it. And patent the idea.
Yes please!
I would recommend clearance hole on the top plate, and tap the bottom one. That will definitely get rid of the "weird" feeling in the transition between them 👍
"bridging" is a very real problem (even more so in wood!)
That's what I did.
Good job. A lot of work done off camera. Thanks for sharing.
Indeed. It's very repetitive, so I suppose it's boring to watch.
@@Rustinox ...but what you did share was far from boring!
Hi Michel, just sitting down to enjoy this my mate, looking forward to seing how it goes 🎉 thanks for sharing
My pleasure, Ralfy.
Hi Michel ☺, looks like you'll have a working gear when it's finished, full mark's for making ,and adapting, as you go along, and that's what makes your video's more interesting, many thanks mate, stay safe, best wishe's to you and your's, Stuart UK.
Thanks Stuart.
Don’t you love it when two halves of a plan come together?
Absolutely :)
Michel, instead of having to make up the proper thickness of packing for your shaper vise when the part can only be held on one side of the jaws, try using a relatively large diameter bolt & nut to quickly make a DIY machinist jack. Of course, you'd need a selection of bolts with different lengths. You could also use a coupling nut with the bolts or threaded rod.
Well, I didn't have the right bolt. But this worked just fine.
To measure the diameter, use a caliper from the bore to outside diameter X 2 + the bore size gives you the outside diameter size, very interesting video thanks, from Coventry UK 🇬🇧.
That could work too.
Heh heh, I don't understand anything I say either Michel! Thanks for your sticker, it will be the FIRST on my new cabinet door!
First! That's cool :)
Ahhh, single point gear cutting. I am familiar with this 😅. Noisy, takes forever, but it'll get the job done. Though I do not envy doing 125 teeth 🤣....
Switches to a real cutter 🤣. Good call!
Cheers!
It's indeed a bit violant :)
Enjoyed….great discussion/craftsmanship/setup solving
Thanks.
If you do not have a large caliper to measure large diameters, you can also use the micrometer dial on the cross feed. Simply bring the turning tool to the center, in this case the bolt, set the dial to zero and turn it back to the desired (or to be measured) large diameter. If the center is difficult to find, you can also take the starting size somewhere else, even the tailstock quilt. You can measure this with a regular caliper and add half the diameter. Not as accurate as a large caliper, but certainly more accurate than a ruler or tape measure!
That could work too.
The king of recycling
Thanks.
coming along nicely.
Let's hope it will work.
@@Rustinox I am sure it will.
In the title it said 120 tooth. Shouldn't that be 127T?
@@RotarySMP I have the 127, but not the 120.
You are my real hero of improvising! Nice work! .....i learned a lot...again! Thank you! 😀
I'm not a hero. I just make things :)
G'day Rusti. Great idea bolting the 2 plates together. As the old saying goes, "where there's a will, there's a way". Not easy at times holding flat plate and machining it. Especially with the intermittent cutting that is hard on inserts. Cheers, Aaron.
Just go for it.
Thanks Rusty, nice approach to making this gear.
Using the steel you had and making a gear cutter.
Nice work.
Thanks for sharing and have a great weekend. 👍👍💯
Ditto!
Thanks.
Interesting shaper setup. I might not have thought of that. Shapers are so versatile. Cheers
On a shaper you can make whatever you want. Just go for it.
I prefer to tap by hand as well. As you say you get better feel for how it is cutting. The gear is coming along nicely. It look's like it is taking a while, but if you cant source a gear then the only option you have is to make one.
Indeed, it takes a lot of time. But that's OK.
Hi Michel. Outstanding project. Breaking taps is a given, no matter how hard you try not to. It’s that split second before they do when you realise it’s too late. 😮🥴😱😢 I so enjoyed seeing how you tackled cutting the gear. You never fail to surprise me. I look forward to seeing the new gear being successfully put to use. 👏👏👍😀
I still have to finish it.
Very entertaining and educational as usual thank you very much Mark 👍
Thanks.
Lovely work as always Michel. I always look forward to Friday because of you!
Thanks.
Great video Michel. I’m enjoying this one. It’s horrible when a tap breaks. I broke a tiny drill in a part recently. I was lucky that I could punch the broken bit through the hole. Can’t do that with a tap 😢 Cheers Nobby
Indeed, breaking taps isn't fun.
If there's ever an apocalyptic metal shortage, you will survive 👍
broken taps are the worst 😩
Good one Rusty !
Lol. Thanks Dean.
I like the home made stuff. The way you are doing this is quite ingenious & free of course. Great video as usual.
Steve.
Thanks Steve.
If you never broke a tap you never tapped. Good save 👍👍👍
Thanks.
Another good video. You are a very patient man as well. Cheers.
Thanks.
Great video, love your sense of humour. Please tell me and the rest of the viewers where we can buy one of those tape measures that measure down to microns as I feel this would be a great accessory to my workshop.😂😂😂 Cheers keep up the marvelous work.
That's classified information.
Alloy soft drink cans make really good thin shim stock .
Indeed.
What’s more, really consistent thickness. Remarkable considering the number are made, and how they a formed.
A fly cutter and a gear (almost) in the same day. Awesome.
Almost :)
Just had to mill out a broken tap myself.. it was a close one too. I was most upset about the tap, it was one of the better ones in my collection.
Glad it worked out good for ya.
Greetings from Indianapolis Indiana 👋
Well, now you have to invest in a new one.
My friend just did something similar where he put together three plates. He drilled holes in the two outer plates and welded through the holes to the center plate. seemed to work okay.
Your method looks nicer than his 😁
Thanks for sharing
Cheers
Thanks.
Excellent job. The only thing I would've done differently is to use JB weld on the 2 plates before screwing them together.
No need. It will work as is.
Looks like a nice gear. Thanks for sharing
And it works :)
Looking good. I hope it works.🤞
I hope so too.
2 flute carbide ball end mill for digging out taps
Good tip.
Awesome entertainment!
Sometimes a walk around the local metal scrap yard can save hours of griding drilling and tapping... but not as much fun for us to watch. 😎
Re the measuring, I recently bought some cheap vernier calipers from Ebay and Temu, so I can have some "basher" calipers to leave laying around in tool trays etc. It's good to have them in arms reach and not need to get out the expensive ones.
They were actually quite decent in terms of accuracy. For your gear you could have used a 200mm vernier, I got one for about $13.
Well I don't have one.
Nothing to say just a obligatory algorithm boost for the channel 👍👍
but isnt a algroithm boost saying something?
Useful.
Another Video Michel. You have a lot of patience as well. Cheers.
Thanks.
Looking good rusty, great video, keep'um coming.
Will do.
Great video, thank you. Watching this today is pushing me to do something with my rotary table/dividing head. I've not used it yet. I never even set it up on the mill. Interestingly, I also watch Machining and Microwaves. I also have no idea what he is on about but love to hear the passion and watch the machining content.
Lol. Thanks.
Hi Michel. Excellent progress, great to see the shaper getting in on the action too.
Seeing you make this gear out of two plates made me think for a moment that this would make a great anti-backlash gear, not that you need one of course!!
Have a great weekend!!
Thanks David.
You have to lube that tap, reduces chance of breakage a lot.
I did.
@@Rustinox Ah, I see. Sorry I didn't notice.
@@BronzeAgePuritan No problem :)
Looking good!
Thanks.
The sigh about the broken tap is familiar to me somehow!
Unfortunately :)
Michel, i never like fly-cutters, to me they look like an automatic ninja-machine😄
They do :) Just be careful.
You’re a resourceful fellow, Rusti! It’s looking good 👍
Thanks.
Delightful job so far Michele! Hoping to a successful completion next week.
Thanks. I hpoe so too.
Looks good,Michel.Thank you.
My pleasure.
Thank You
My pleasure.
Great video ! Waiting for the next one.
Next week :)
The gear is looking great!!
Thanks.
I have a special pair of glasses for the workshop. With side protection in a case.
Nice smaller machines. Interesting where you machines originated from?
Celtic 14 lathe: Belgium.
Other lathe: Armenia.
Hembrug shaper: Netherlands.
Deckel FP1: Germany.
Thanks for sharing 👍😎
Welcome.
i thought for a second there we would have a 'side project'......for a 175-200 micrometer ha ha cheers
Well, not really :)
Did you consider putting a bit of epoxy between the two side? It wouldn’t take much. Thanks for the video.
Nope, this is a dry fit :)
A cliffhanger. Well done Michel. I hate it when I great a tap.
It's a cliffhanger for me too :)
Excellent work Rusti.
Thanks.
i found with grooving on my boxford shaper that a tool bit with a swept angle is alot better so the cut is not so sudden
That makes sense.
I really like watching you work because while watching you work I'm not lol
But working is fun to do.
Spiral taps, save taps ;)
They break too.
Je n'ai pas d'outil pour mesurer des cercles aussi grands. Ce que je fais, c'est mesurer la circonférence et la diviser par pi. Tu seras surpris de la précision obtenue.
That could work too.
Hi Rustinox Good video as usual. I like your milling machine - Deckel? I have an Aceiira F3 and it looks as though your collets are similar to the W20 style, but longer.
Good luck with the gear. John
This is a FP1. A very nice toy.
Interesting pliers.
Shoemakers pliers.
Rustinox gold as usual ❤️😁👍
Thanks.
When dividing for a gear, there is always that horrible thought will the end show a thick cut or a thin cut or will it work out correctly... Good onya
We'll see. I still have to finish it.
good video rustinox
Thanks.
doesn't work, doesn't exist! is difficult, often exists👨🏼🔧💪🏻👍🏻
Spot on.
That seems to be coming along nicely. Those damn taps have no respect for you at all.
Indeed, asolutely no.
Why do tap wrenches have knurling on the ends? My favourite, inherited from my father, had particularly gnarly ends till I polished the ends.
My home made wrench hasn't knurls. It works just fine :)
Lovely old job
Thanks.
Could you measure the diameter with verniers from the inside hole to the outside edge, + 1/2 the dia of the inside hole, then times 2 for a proper OD?
That could work too.
120 teeth? That looked tedious to do!!!
It is. And I did cut the teeth in two passes.
This must be a first... using a tape measure on a machining video😆
Exciting, isnt it, cutting lots of teeth on a gear. Praying you dont miscount a mess it all up!
Well, I almost had a mishap.
Your machine screws are adequate enough for the use this gear is going to see. If someone was doing this for a higher torque or heavier use, rivets would be a much stronger choice for low temperature fastening. Im not trying to denigrate your choice here. We all use what we have available in our shops. Im just making an observation that might help someone out there 😉👍
Well, what I would do and it is what I do, is to drill some holes close to, but inward of where the teeth will bottom out, on one plate about 10mm, 3/8” in diameter and weld the two plates together. A few holes closer to the center would be welded as well. He agrees that it’s the best way as well. Heavy rivets will work as well as long as they’re riveted properly, which is hard to do in a home shop in parts this heavy. With the screws (they’re not bolts), I would cut the ends a couple of mm short and thread one plate. After screwing them in as tightly as possibly, I would then spot weld, with the MiG welder, preferably, on the threaded end. That would also make for a tight, permanent connection.
To install rivets, I need a torch... that I don't have.
@@Rustinox not to hijack the conversation, but i don't fully agree, you have a forge right? Heat up the rivets in the forge, drop them in the gear and knock them in
All quiet on Western Front not sure about the future with the current Leaders !
Christopher from down under
We'll see what happens.