I am a 72 year old retired master machinist. I have made dozens of throated worm gears similar to this one but never with so little machinery. With CNC machinery it is so simple, with manual machinery it is sometimes nearly impossible. Hats off to these guys. Superb work.
Education is the main factor in under developed country if they had opportunity to learn using modern machine tools they can also perform more better... but they learn by practice In this kind of shop .
There are two key pieces of machinery here, the horizontal mill and the dividing head. The 4th axis on the mill is useful, but you can actually bolt the dividing head to the bed to get that angle. This is the heart of a hobbing machine. The cutter can be shop made to the shape of the tooth. But this is just basic hobbing. The real problem here is that they are using aluminum for the gear, that will not wear well and so this is at best a quick fix that will need later replacement.
My dad was a machinist. On Saturday I would ride my bike to the shop where he worked and watch him standing at the Bridgeport milling machine turning a block of steel into a mold that would be used to make a plastic part. I loved and admired my dad. He’s been gone for many years now and I still miss his smile.
*_As another great example, of which, around the globe, there are many:_* go to Cuba ... where the Great Majority of Autos are from the USA ... generally of vintages starting from the 1940s through the 1960s; where some are a hodge-podge of various hand-made mixed and matched parts but MANY of them look NEAR NEW!
not really its been my experience older machines were designed with service and wear in mind unlike today where things break right after the warentee expires. and at 70 yr old i would hope the machinists knowledge and experience are equal to the task of reproducing a part from a worn example. personally i wonder about the metallurgy and was the gear hardened because no matter how perfect the size and shape is it would be useless if it were not the right rockwell !
I worked in the oilfield in venezuela in the boonies. A mixer broke a gear similar to this one. Local crew took it to village. Next day a new part was delivered. Made in a "hole in the wall" machine shop. Amazing workmanship.
It's not what the shop looks like but if the guy has the machine and the skills to use it. There will be machinists jobs forever because even if you can duplicate how a part looks with 3D printing, they do not have the strength of a machined part. But you know what, I could be wrong. Maybe, they will have AI scan it, put a block of metal on a computer driven Bridgeport machine, and an hour later, voila the one of a kind part.
Knew an old Brit machinist who worked in Pakistan for years he always commented on how they could make anything you needed from scratch in a few hours with minimal tools while squatting on the floor. And these confirm he was not exaggerating.
"I heard from someone in the old days...." Yeah, that's how a lot of BS starts out. These guys are using some clapped out machines and bowlegged calipers. I'm sure they could build a Space Shuttle in two days. Yep.
@@dcw56 It's sad you take that view. Well, without intending any disrespect to you, I suppose you work or have access to machining centres that cost millions of dollars? But these guys get the job done and manage to repair stuff.. NO BS THERE..
@@camiemengineer Pakistan did manage to build their own nukes (they are a nuclear power) back in the 1970s. Now... I don't think this guy or these machines were used to build them. Well maybe when that mill was new it was used in their arms industry. That said the old bronze worm gear still looks better than that "new" light alloy one he just made.
@@utidjian I am not suggesting that Pakistan does not have state-of-the-art machining centres. But there are many, (or so it seems), family businesses that have to make a living with old equipment, because they cannot afford to replace with new machines.
No, I'm sorry to sound like a bad person, but these men only know what they have been taught, and their education is severely lacking. Using that aluminum skew gear in place of a bronze gear will result in a VERY premature failure of the part, AND the adjacent running gears. That is not a good repair for the return on the time. IF they know how to do it right in the first place, then why not DO IT RIGHT? If they don't know how to do it right, then why crow about this video? Either way, the part is far sub-standard and it is the weak link in the gear train which can cause total failure of the entire train of gear driven shafts. There is a point where "cheap" no matter how costly a proper part costs, is not cheap at all, but costs multiple values in dollar amounts. Do it right the first time and get the job done properly, even if it costs the equipment owner from putting more dingle balls and fancy painting on their vehicles. (Have you seen the decorations on their hauling and excavation equipment? Save that artwork money and do a proper job of repairs.) I know! That sounds mean. It is economics!
@@dcw56 Surely the intention here is to make a mould? I mean that would make a lot more sense that people who are much more experienced and knowledgeable than [a commenter on TH-cam who pumps up their own ego by pretending to be a lot more of an expert in something that they know nothing about, i.e. you] would know more than you. Even the most basic engineer would understand that an aluminium part would fail almost immediately. On the other hand, trying to directly machine brass would probably be quite difficult. So I imagine, Mr. Expert, that the intention here is to use the aluminium part to create a mould or former into which they will cast a bronze part. And although I am not a mechanical engineer or a machinist, I have sufficient education to draw this conclusion. Which suggests that it is you, personally, who is lacking the required education to be an effective participant in this technology driven world. So go boil an egg.
Couldn’t help but watch 😂brings back memories of when I worked tool and die. Its amazing how much work goes into not only creating the parts for the machine but the parts that make up the machine that makes the parts. I ran a 13 foot tall drill and prepared the largest slab of metal in the shop that makes up that machine. I think it was because they could see how skilled I was. I did all that with out any school. Started in the stamping department back when Eminem went big for low wage and caught on fast. I miss that job.
My dad recently passed away, he was a retired jeweler, he adored and owned a atlas lathe. He would make dice for manual engraving. I missed him so much. Fond memories spending time with him 😔
The cool part of this is how he uses the involute cutter (with a tooth missing), the dividing head and the ability of the mill table to pivot to the correct angle for that helical gear. It takes him awhile and patience to get that right. His cutter was fixed on the horizontal shaft so he had to work with that. You can tell he is not centered on the work piece because he uses the y axis handle and pivot point to keep dialing it in as he travels through the part. Once he has the tool path right he can go back to the dividing head and set it at zero(start point). What if he didn't have a sample part? I give him credit for his use of what he has to work with and getting the job done. Old school machinists are hard to find these days. They work with what they have and do the best they can with it.
@@UNcommonSenseAUS I wonder how much it would cost for that Hass machine plus operator for those few minutes, versus these guys for presumably a whole day. I bet its close, but maybe there's a question about availability of such machines wherever this is (Pakistan, at a guess).
@@fartingfury about £40-60 a hour but you have setup time aswell to account for, it will certainly take a good few hours for a modern machine shop to machine this component especially since they have no drawings to work back from. A no way is the operator of a 6th axis haas just gonna push the green button a come back when the cycle is finished, you have to prove out your new program on single block and that takes time itself. If the tools cut quicker than hhs cutters uses in this video then that's because its carbide and is expensive as hell adding to costs! A naive comment to say a haas will do it in only few mins!🤦♂️
Mating worm if it’s a multi start it will have a large jump and fixed center distance it will bind up.Bronze is the material that must be used aluminum will wear out in a instant.
I started watching this video with high hopes. I've been a machinist for over 40 years. Owned my own shop for almost 20 now. Worm gears are made from bronze for a reason. If you've ever machined it you'll understand. It can be tough but not brittle. The replacement he made is an oversized paper weight if he is using aluminum, which is what it appears to be. If it doesn't fail right away, it may keep you up and running as long as the correct replacement arrives soon. But now you've spent your money twice for the part and twice for the repair time.... I'm seeing the number of views this video has and thinking wow.
@@soni204 Sheer stupidity then. Buy a cheap grade of steel like 1018 or 12L14. It's cheap and you can oil quench without spending the money for heat treating. At least then you have a chance with the new part. It will take longer to machine but won't fail right away. There is NO chance with the aluminum and to say "what they can afford" is just ridiculous.
@@sndnmytrnks I am a tool and die maker with My own cnc shop. You cannot check precision bores with an beat up caliper. For all those who think this is great work, Wait till the customer tries to fit it to the the shaft and its just a few thousandths small, then what? and i think thats cast aluminum. You couldnt pick a worse material for longevity
@@deeferdownunder Aluminum can be hard anodized, and with proper lubrication and light service it might last longer than you would think. No where near bronze, but maybe they could not get the bronze material for an extended time.
And guess what: Don't even think about retiring in the US. - I never worked so hard since I retired. The wokies convinced the kids they had to go to collage for 10 years and get advanced degrees in tings like urban studies and diversity. They ridiculed anybody who wanted to get into the skilled trades - Now there is nobody to replace us (And trust me, CNC is NOT the answer to everything, ) Now us old timers keep getting offers we can[t refuse to come in and do a job or repair a machine because we are the onoy ones that can get the jon done,,,,,but we are dying off ann when we are gone, the skills will be gone with us.
@@mathewmolk2089 I'm a US citizen and retired. I was a fine art photography and art teacher in a public school. I worked for 21 years in NY, which provided a pension of about $2200 a month That, together with our Social Security checks, and sales of a few pictures gives us about $5000 a month, which is enough to pay the mortgage on our new house, which we put 50% toward. Anyway, we have fully paid health insurance courtesy of the school district too, no debt, and are getting by. The pension was a life saver. At the end of my career, I told every kid who would listen, to go for a job with a pension. Most didn't listen and wanted to get rich. They will do what they do. As far as skills being lost. That is a major problem. Someday, many will wake up and think, I'm going back to school to be a machinist, a welder, an electrician, a cabinetmaker, or some other trade that pays very good money because no one is left. That is when there will be a rebirth of trades, but I think it is still far off. Now, they want to be Taylor Swift or some other musical star. She is going to make $600 million just from her concert tour next year. She will become a billionaire. Can you blame them? It won't work out for 99.999% though. then they will have to do something that pays the bills, like me. I was fortunate to have a teaching certificate in addition to my major in art. All the best to you. I do not know what we would do if we only had Social Security. I know it would be a miserable life.
I’m in the same boat. Older machinist looking to retire. I’m not sure my employer will be able to find a replacement for me. I feel guilty. There just aren’t any skilled machinists. I don’t think "woke" had anything to do with it. The unions got busted in the 80’s, all the apprenticeships went with them, and they started sending all the jobs to China. It was all the baby boomers that wanted their kids to go to college. I do prototyping for a company and the young engineers I see now who grew up with 3d printers and went to STEM and STEAM programs are going to do great things. They don’t know shit about machining, but I’ve worked with a lot of engineers that didn’t . I’ve seen kids do projects by themselves that a whole team would be lucky to pull off 20 years ago.
@@mathewmolk2089 It was not the wokies. After WWII, the government made the GI Bill and a college education was within the reach of every person who served. From then on, everyone promoted a college education. Not that it was wrong. Solid statistics showed that a person with a college education earned significantly more than one who did not have one. It is true.And, most parents wanted their kids to go to college. Additionally, many people came here with only a suitcase or the clothes on their back. They worked hard, then sent their kids to college. Some of these kids have become famous, rich, or both. Others have become important writers, composers, musicians, actors, directors, doctors, businessmen, and politicians. Without a college education, and usually more than one degree, you are at a disadvantage in this country. You earned a good living as a machinist, but I bet the guy who was your supervisor and had a degree in mechanical engineering earned a lot more. Never criticize those who have a college education. You only make yourself look dumb. By the way, today it is even nececessary for the local cop to have a degree in criminal justice from the local community college.
I just assumed he used aluminum was either to show off his skill as a machinist, it was going to be used as a casting blank, or as a prototype before machining expensive bronze.
It wouldn't work as a patern because it's not oversized to allow for shrinkage, on top of that the shape of the gear teeth would be impossible to remove from the sand.. my guess is it's just a temporary part to keep a factory running until propper material can be sourced
If you can't respect the person's skills, be it Aluminium or copper or brass, but don't pass negative remarks learn to appericate one's skill, it is his year's of hard work & skill, he had made this Gear.
Unfortunately we are looking at skill applied in ignorance, I live in Africa and it is also common there. It often comes from rote learning where the watcher believes he can do what the watched can without realizing the stuff he hasn't seen is even more important. The knowledge of metallurgy, heat treatment, strengths of materials, lubrication, item design, shock loading, the list is long and all mechanical engineers reading this will know I am not insulting this 70 year old but feel sorrow in my heart that his ignorance in this guise is sadly being perpetuated down further generations. Education from grass root level is essential grow nations.
What kind of equipment do you think builds new equipment. That said the machines you saw in this video is still used daily in machine shops in every country on this planet and still available for purchase new. My point is a very large portion of machine work done in the world today especially 1 off work is done with manual equipment
@@gullreefclub The gear in the video wasn't the crap we see being made today.... no computers... and other technology. Just solid old school machines that last.
Reminds me of the machine shop I worked in around 1972. That might be the same horizontal mill. I saw a shaper in the background. I miss the old manual machines.
As an emergency measure I once made a replacement worm gear similar to this in HE30 engineering grade hard aluminium in order to replace a bronze gear that had worn out, the aluminium gear did the job and got us out of a bind but subsequent testing to see how long it would last showed that the wear rate on the aluminium gear was something like 100 times greater that of the original bronze gear and by comparison the wear rate of a bronze gear (NOT BRASS which is a pretty useless material to make skew gears out of) is about 100 greater than a hardened steel pair of gears, proper lubrication being applied in each case
You could also add some nikasil coating on the aluminium as we do it for aluminium motorcycle cylinder blocks, but i don't know if they have access to that technology
@@kukipett An interesting idea, we have hard anodising which prevents wear for a little while but it wears through creating an abrasive paste when the remains of the anodised layer mixes with the lubricant and greatly increases wear. My suggestion is always to use the right material for the job along with the correct heat treatment before and after machining, finish grinding and then lapping and polishing as required. I don't know if the pattern gear in this video is brass or bronze but I will say that brass is a useless material to make a gear of this type where there is a sliding action between the gears, with a rolling action and low torque brass may not be too bad but the correct grade of hard bronze is the vastly better material
That's what I was thinking also, I wasn't sure if it was Alu what they were using as a replacement because it seemed like a massive downgrade from the original. BUT it's probably what they have to work with because they also used a cutting tool with a broken tooth. So it might be like sitting on a remote island, having to build a two story house with only a kitchen knife😉
I had a friend who bought a lathe machine but didn't know how to use it , later he became proficient with it and the rest is history! If you have the drive and passion anything is possible!
I recently had a company in Sydney manufacture a very large double throated worm gear for a worm drive differential. The nickel bronze gear was spun cast initially as this creates a much stronger gear. Machining took a week! And it had to mesh perfectly with pinion. Overall 6 months. People don't generally make gears like this any more!
Excellent job, people are praising the old man, and rightly so, But the man who did the set up and machined the blank is equally skilled. Many congratulations from a long retired machinist from Scotland living his last days in Argentina. 👍👍👍👍👍
Hello Kevin; Everything here seems like I am arguing about this vid, but what is thought of as "primitive technology" as you put it is what was used in WW ONE to make parts for machines back then. Those machines still work perfectly if taken care of. The FACT the the guy had to jam a screwdriver into the over arm on that horizontal mill shows they can't even be bothered to make something as simple as a gib. Something I was taught to do with a file back in the 70s when I was still in high school. There is no mystery or craftsmanship here. This is a video of how to do things all wrong and in a slip shod way. He knows what someone long ago showed him, but if he had a new horizontal milling machine, I imagine he would wonder where to jam the screwdriver in to take up the slack in the gibs. (Start by adjusting the gibs in the firs place, IOW..)
@@dcw56 primitive technology was the wrong terminology that I used. Basically saying these guys sit on the floor hold parts with their toes and still manage to get the job done. I don't think that crankshaft is going to last forever but they make do with what they've got. I think that's my real point. And it does look pretty primitive but they do get the job done even if it's only a temporary fix.
If you think this is primitive technology then maybe look up what sort of machines Rolls Royce uses in their factories.. Rolls Royce is still using the same machines they used back in the 50s and before
A machinist working in a 6'x6' corrugated shed in Tullos, Louisiana made every spare part needed for drillin' rigs and pumpers in that little one-horse oil-patch town in the 1940's and 1950's. Mr. Stiart (sic) could make anything needed to get the job done.
Yeah, we call it no such thing as cant. If they ever have to bring back the oilfield, I don't know where their going to get the experienced. Gonna tak a wile.
My dad was a welder by trade but had a lathe in cellar. I too watched him for hours down there on many projects. So I admire very much your skills. The piece you made was a beautiful piece of art.
I was a CNC machinist for years, I love to watch people in different countries make parts or products, with what we consider primitive tools and equipment. We are use to getting our products made in huge factories, with millions of dollars worth of equipment to make the most basic of products. In these 3rd world countries they are making beautiful pots & cooking wares, building parts like this gear on equipment that is ancient by modern standards. These people have the skills and experience to make beautiful, working, and purposeful items, from recycled or raw materials. I know few machinists here in the US that could use that equipment and make the same part, as he does. When you don't have the right tools for the job, you improvise and use what you have and get it done! Hats off to these skilled workers!
A Lathe and Horizontal mill are NOT primitive tools. In a tool and die type shop a customer can bring in a one off job and a tool maker will be in the office typing the invoice before you can be done writing the program and loading the tool changer. CNC is not the answer to everything. In fact there are jobs (like welding up a gear with a couple missing teeth in a bevel gear and machinating them) that are totally impossible on a CNC machine. The Lathe and Bridgport can still get the job done. The only place the cost of a CNC machine can be justified is when you are turning out multiple parts. On onsie-Twosies CNC will never pay for itself,,,,and most of the time is actually slower then manual machines when they are in the hands of a skilled machine hand. ,,,,,, Hell 90 percent of CNC operators cannot even re-grind a drill bit.
@@edmundooliver7584 About 50 years ago, I saw a young apprentice guy get his long hair caught in the chuck of a drill press. It wasn't a pretty sight. Not much emphasis on safety back then.
Working around that type of equipment it's best not to use gloves or wear loose fitting clothes. Which both applies to these artists. I worked in a boilermaker shop for years and saw the result of a fellow getting a glove caught while use a large drill press.
Considering the equipment he had to do this job with, I think he did an admirable job indeed. I’m no machinist but my Father was and I got to watch him use various pieces of metal working machinery growing up. This man had a cutting tool that was on a shaft that wasn’t true and it had a screwdriver jammed in to keep it from moving. No safety equipment whatsoever. At 70 years of age he’s lucky to have his eyesight.
The shaft actually is true. Watch again, that final spacer is off-center (cam) ground on the OD. If the shaft wasn't true you'd see the machine either lock up or dance around (from vibration).
Interestingly enough, the old Gamewell type municipal fire alarm boxes had a clock spring powered gear train like a clock, made of solid bronze they had a different feature from clocks- a bronze disk about 1 to 1-1/4" diameter with teeth on them that resemble gears, but they aren't gears, they are notched in a way to create a numbered code based on the number of teeth and their pattern of gaps, as it turned when the alarm was actuated, a set of contacts rode on the teeth and gaps which sent a DC signal out. The remarkable thing was every one of these code wheels was unique and one of a kind because a large city might have several hundred units or more and they each had to have a unique number, so it wasn't like they could set up a machine and make 500 identical code wheels and spread the costs of the setup etc over 500 pieces. Also, I have a set of blueprints the city provided machinists in the 1930s to make these, even the angle and width of the teeth varied depending on a few things such as how many teeth had to be cut on it and leave room for gaps, a box having a number like 9799 had to have different teeth than one that had say the number 322 since the diameter of the code wheel was limited and couldnt be made larger and still fit the mechanism.
1st rule of turning: do not get your hands/fingers anywhere near the piece while it is turning. 2nd rules of turning: do not leave any tools that can fall while the piece is turning. 3rd rule of turning: short or tight long sleeves when working with a lathe.
This is something that is done hundreds if not thousands of times a day all over the world! His machining is anything but precise but he made it work! Any low level machinist in the US would have easily turned out this quality work or higher pre WW1. I was taught to hob gears in high school machine shop, in college/apprenticeship we went far beyond that! I suppose it seems amazing for those that know nothing about manufacturing!
You, sir, seem to understand. What that guy did is not magic. It is not hard to do. It is not even high school shop class quality on any kind of manual machine. For some reason, the folks who aren't actual manual machinists, (of which there are tens of thousands still in the United States) seem to think this is some king of magic. The man knows how to do what he was taught, but it is still hack work, and the video description makes it out to be some kind of miracle. It is common work in most other countries.
I couldn't help laughing as he was using chalk while pushing the sector arms out of the way. If these guys had a little bit more knowledge they could do much better.
@@rotax636nut5 Thank you, sir. I did not mean to tell people that this guy was not good at what he knew, but what he knows is the same thing European and American machinists knew over 120 years ago. People thought I was being mean towards this man cutting that (sorry, but poorly done) gear. It is nothing unusual, even for a guy like me who has worked in an ALL MANUAL machine shop for decades. Yeah, I'm an ol' fart. Our Almighty God and Savior bless him though! He probably has a kind of hard life. But his machining is no miracle and not even good enough to be admired. I'm glad for him that he has a job, and hopefully brings home the bacon to his family.
@@dcw56 When OSHA and EPA and NAFTA came in and the commie teacher's unions got the schools to replace industrial arts with diversity and urban studies classes it signaled the end of the skilled trades in the US ,,,,, Take a look at 30 year old American men. - They can't do ANYTHING. They don't even know how to change the oil in their car much less be able to set up a universal mill (which is not rocket science) The average American male is a totally helpless subject of the nanny state. Take away their smart phone and they can't even find their way to a gas station.
It’s interesting to watch these highly skilled craftsmen working with such antiquated machinery. I have nothing but admiration for them. But I would really like to see some of these parts fitted and doing the job as intended. I think that would be a satisfying video to watch.
I've got an almost identical set up as that mill in my workshop except its a Richmond (midgley and sutcliffe). Might even be a bit older. 1930's ish. With a Cincinnati dividing head. Runs great.
I've always regretted not continuing to learn to be a machinist. I had an older friend that owned a machine shop and constantly offered me the chance to learn the trade from him. But the down side that caused me to lose interest was his son while using the lathe the piece came loose and hit him in the head. He was mentally and physically never the same.
I'm sorry about that young man getting injured. That is not the fault of the machine, but the machinist. It is too bad that he had not been properly trained in the trade. Machinist is the best of trades. You can make anything except what a tool and die maker can do, but what they do is extremely specialized. Machinists can do almost anything if properly trained. It truly is the best of trades.
@@dcw56 I don't care how trained you are (which is only a minor prerequisite to experience) mishaps are going to happen and you can even get killed. "Safe" is only a word in a machine, wood, or fab shop. Every machine in there wants to take a chunk out of you and ruin you day. If you work there long enough sooner or later one of them will get you. The only question is when, and how bad. It's shall we say "Cast in Iron" -(Steel mills and foundrys are great places to get hurt too.) There is no such thing as a totally safe workplace, Or anywhere else for that matter.
@@mathewmolk2089 How long have you been a real machinist? I don't mean a CNC button pusher, but a REAL machinist? I'm near 67 and still have my head, my butt, two full arms and two full legs along with 10 fingers on my hands and 10 toes on my feet. I will not accept that this guy did a good job just because the parts match well enough. They have to match perfectly, or you have a very short working life for the parts. See what these "trained" monkeys say when the part comes back in a year. "We make a new one, just like last time..." Unless you are a REAL machinist, stifle it, please. BTW, I made 42,000 parts in my machine shop since January 2020. No injuries Properly trained. Properly vetted. Properly aware of machines turning 30 pound work pieces. Proper!
What a fantastic job he did. Any Western machine shop would be delighted to have him. We have this perception that these are back street workshop chancers because of where they come from, but forget that they may be just as qualified as any. Fair play to them. I love the way the screwdriver is jammed in! Well done.👍☘️
@donalfinn Thank you! Being a German Geologist, I've spend decades in ""under developed"" countries. Our western arrogance towards those people never ceases to amaze me! Countless times we needed spare parts, to be ship in and worth thousands of dollars. And then, bingo....a local mechanical , or electrical workshop produced a replica, even better than the original. For a handful of dollars....and a pad on the shoulder....how patronizing and unfair? Just because people are poor, and so are their countries....does not mean they are dumb and stupid!!! I have seen cars and trucks rebuilt....very, very few western workshops would be capable of doing that. As for the screwdriver....that is the essence....improvising.....and it works! Cheers
He is a very skilled machinist, but he should have some eye protection from splinters and swarf. His beard was dangerously close to getting caught in that milling arbour!
I have to say some people's ability is not just amazing. There is barely words to describe their ability. To machine this, is one such case. All he used were micrometers and a lathe, little else. His skill, acuracy and expertise is such, few could match.
The original gear is made from brass for a reason. I’m not sure aluminum would last long. Also, the one they are copying looks fine. Maybe the one they are replacing was destroyed. It is awesome that someone could make this. It’s an impressive skill.
The original gear-wheel is made from bronze to be able to withstand loads and wear & tear. It is usually driven by a hardened steel 'worm-gear'. I am familiar with these types of bronze gears. They are designed for lots of abuse. The aluminum replication will not hold up very long under load.
@@patverum9051 if you mean they want it for a patern to mold the casting sand then no, it would have to be made oversized to allow for shrinkage and this wasn't oversized
Good to watch a craftsman. Doing his work. I worked for a German company . And we made a lot of unusual. Parts. But as technology grows . Finally they put in CNN machines. And even this they did great work. , true craftsmanship. Was lost.
Im a 37 year machinist and its great to see a good product made under these conditions. The screwdriver used to jam the arbor rest in place is still tripping me out. But how many people were expecting him to get his beard caught in that spinning arbor nut? You know its had to happen to somebody at some point.
Esto es lo que se llama conocimiento y habilidad manual, cosas que se han ido perdiendo con la automatización. Es un trabajo admirable, y logrado con máquinas herramientas que dependen de la pericia del operador para lograr un trabajo perfecto. Felicitaciones.
The ways on the machine are probably so worn that the original clamp won't lock. Some arbor with a dogleg and think only a couple teeth on the cutter were actually doing the cutting.
There's always an endless list of you clowns repeating the same criticising comments over and over again like a bunch of mindless parrots all thinking someone cares.
Ola ! Muito difícil, mas vocês dominam a técnica, e sao excelentes profissionais. Vi que um milímetro de diferença nao funciona como deve. .vejo vocês muito atentos a isso. As medidas. Muito bem. Gostei. Deus te de muota saúde. Abraço do Brasil.
My dad's 99 years old still running his machine shop still making parts been doing it for a long time excellent I think he's a genius he's also learned how to transition to CNC machines as well as old school.
Barney I Love these guys and those with similar skill. They can look at what's needed and the intended purpose and produce it. CNCs etc are tremendous but the basic ability to see what's there and what's needed and produce it so it works undercuts everything else. Made me think of our social and political problems and situations lacking the basic real physical world and natural laws that the same as building and bridge have to have the basics of mathematics and engineering to work. We do live and operate in a physical world. Deep Huh !
Can't substitute aluminum for bronze. The newly manufactured gear is of little to no use when installed in the original machine. It makes a nice novelty paperweight or door stopper instead.
There is only 1 problem with the Aluminum gear he made... If it as to replace the brass gear they used as a template, the Aluminum gear will not last as long as the brass gear would and it will probably fail prematurely on whatever worm gear is driving it Aluminum is very soft and can bend way easier that Brass. So whatever machine it would be put in will not last as long as the Brass gear would. just saying. Gears also need to adhere to tolerances down to the thousands of an inch (.001) if not the worm gear driving the Aluminum gear will wear much quicker. As for the skills i give him mad props on doing machining that way but the machine will suffer if it isn't in specs don to a (.001) of an inch.
Your right, but as a qualified technician in mechanical engineering I will say that both aluminium and brass are both highly unsuitable materials to make this gear from, the material should be either C90700 (SAE65) bronze or S45C carbon steel which will need to be heat treated, checked for dimensions, possible finish ground then lapped to the correct surface finish/texture on the gear teeth before use. With all these videos that demonstrate 'amazing skills' it's not enough just to be able to manufacture the item, the product also needs to be made of the right material in the right machinable condition in the first instance, then heat treated and ground as required then polished and/or lapped before it will be suitable for reliable use. This is why OE gears and parts in general are expensive and why these well meaning and skilled artisans working in sheds with dirt floors are cheap. No disrespect to these guys they are very clever but lets not make them up into something they are not..
@@rotax636nut5 As a machinist at the trade for decades, I do not think these guys are either "clever" nor (at all) artisans. I do not mean to demean them. They are doing what they have been taught, and seemingly have not progressed for three to four generations. Still doing the same ol' thing to make something work for a little while longer. That is NOT what a real machinist does. We make parts that are at least as good as the original spec, and yes, sometimes that means sending it out for heat treating. Skipping steps because of ignorance or price does not make one an artisan, (I am not an artisan. I'm a machinist, manual machines only) nor does it make you a machinist, or even clever. I understand that these guys may be just working to make enough to eat, but that does not make them an artisan any more than a guy who grows corn or a man who catches fish for market. Using clapped out machines and getting things "good enough" by eyeball does not a machinist make. Fixing the old machine would be a good first step in becoming a machinist. I do understand he needs to eat, though, but that lathe in the shop is only about 10 years old... The money for it came from somewhere. It is not an old machine. The old Adcock, Now that is an old machine. Fix it!
I remember in my apprenticeship days (1963) using this machine technology. Great skill is required. I doubt the young fella doesn't even know what a manual dividing head is. These guys are great artisans in my book.
Yes we do. I am one sitting in my Lazy Boy looking at my retirement. Sadly the pay rate for Machinists has gone way down in relation for the skill level required. When you can go to McDonald's and make 75% of what a machinist makes, sort of takes the desire out of staying in the trade.
It amazes me how alvin and the chipmunks make things properly by hand,bring back the the skilled workers and I know cnc machining is brilliant but I don't think you can beat a hand made item.passion.i hope the videos money goes back to the makers and not in someone else's pocket
My guess, from the looks of the shop, they got about $99 for it plus materials. That piece would cost $10,000 here and you would be lucky to get it in a month.
Yes because $99 is all that the customer can afford and he needs the part to work and feed his family ... no one else will feed the families of either party.
They don't need to worry about thermal expansion of the part - since no matter how hot it gets from the cutting operation, it'll ALWAYS be hotter outside in that part of the world anyhow! :D
@@Jon-vm3qw using the micrometer come as a calculation ??! There are many machinist work like that ,they need a model and they making exactly the same , without using any charts or any calculation ! Didn't you see how they move the table for a angle of gear ??
Nice work with limited tools. BUT that gear or its mating part will last a very short time. The original was made of brass/bronze for a specific reason. Building up the worn item by brazing and then remachining would give a much better product. regards
Yes I agree the worm mating with that gear will wear out in no time!!! I am talking from 55 years experience in machining such things, that material should be manganese bronze or at least aluminium bronze mating steel with steel is a joke!!!
i went to a city collage for 32 years to have access to a machine shop and did lot of things like this it was a blast . sad thing is most would just open there wallet but the day is coming were that won't do and its coming soon so learn something real
Making the gear was interesting and remarkable. But what was really astounding is the machinist didn't look a day over 50, even with the grey beard. (Look at the lack of creases at the corner of the eyes.)
I am a 72 year old retired master machinist. I have made dozens of throated worm gears similar to this one but never with so little machinery. With CNC machinery it is so simple, with manual machinery it is sometimes nearly impossible. Hats off to these guys. Superb work.
it's not nearly impossible if you know what you're doing
@@triariicat8448 said the kid to the RETIRED MASTER MACHINIST
@@doggfriendly "master"
Education is the main factor in under developed country if they had opportunity to learn using modern machine tools they can also perform more better... but they learn by practice In this kind of shop .
There are two key pieces of machinery here, the horizontal mill and the dividing head. The 4th axis on the mill is useful, but you can actually bolt the dividing head to the bed to get that angle. This is the heart of a hobbing machine. The cutter can be shop made to the shape of the tooth. But this is just basic hobbing.
The real problem here is that they are using aluminum for the gear, that will not wear well and so this is at best a quick fix that will need later replacement.
My dad was a machinist. On Saturday I would ride my bike to the shop where he worked and watch him standing at the Bridgeport milling machine turning a block of steel into a mold that would be used to make a plastic part. I loved and admired my dad. He’s been gone for many years now and I still miss his smile.
He’s lucky to have a son like you
Indeed dad was blessed to have son like you
A beautiful memory of a father and son. Its very harsh but its reality. What we think is reality will one day turn into memory.
🙂
Rip bro
you men do some awsome work.enjoy watching you.larry USA
the world wouldn't be where it is without fellas like this
It's impresive to see that a machine made in Leicester is still in service many decades later, superb skills.
thats back when things were made to last! not like today... serious skills there to make gears like that at the best of times.
*_As another great example, of which, around the globe, there are many:_* go to Cuba ... where the Great Majority of Autos are from the USA ... generally of vintages starting from the 1940s through the 1960s; where some are a hodge-podge of various hand-made mixed and matched parts but MANY of them look NEAR NEW!
not really its been my experience older machines were designed with service and wear in mind unlike today where things break right after the warentee expires. and at 70 yr old i would hope the machinists knowledge and experience are equal to the task of reproducing a part from a worn example. personally i wonder about the metallurgy and was the gear hardened because no matter how perfect the size and shape is it would be useless if it were not the right rockwell !
I think that comment was over the heads of most ppl....
Ironic that Leicester has more Pakistanis in it now than Islamabad.
I worked in the oilfield in venezuela in the boonies. A mixer broke a gear similar to this one. Local crew took it to village. Next day a new part was delivered. Made in a "hole in the wall" machine shop. Amazing workmanship.
It's not what the shop looks like but if the guy has the machine and the skills to use it. There will be machinists jobs forever because even if you can duplicate how a part looks with 3D printing, they do not have the strength of a machined part. But you know what, I could be wrong. Maybe, they will have AI scan it, put a block of metal on a computer driven Bridgeport machine, and an hour later, voila the one of a kind part.
Knew an old Brit machinist who worked in Pakistan for years he always commented on how they could make anything you needed from scratch in a few hours with minimal tools while squatting on the floor. And these confirm he was not exaggerating.
This is the first time i saw that they use a caliper
"I heard from someone in the old days...."
Yeah, that's how a lot of BS starts out. These guys are using some clapped out machines and bowlegged calipers. I'm sure they could build a Space Shuttle in two days. Yep.
@@dcw56 It's sad you take that view. Well, without intending any disrespect to you, I suppose you work or have access to machining centres that cost millions of dollars? But these guys get the job done and manage to repair stuff.. NO BS THERE..
@@camiemengineer Pakistan did manage to build their own nukes (they are a nuclear power) back in the 1970s. Now... I don't think this guy or these machines were used to build them. Well maybe when that mill was new it was used in their arms industry. That said the old bronze worm gear still looks better than that "new" light alloy one he just made.
@@utidjian I am not suggesting that Pakistan does not have state-of-the-art machining centres. But there are many, (or so it seems), family businesses that have to make a living with old equipment, because they cannot afford to replace with new machines.
These men have done so much for so long, with so little, that they have developed the skills necessary to make anything out of nothing!
No, I'm sorry to sound like a bad person, but these men only know what they have been taught, and their education is severely lacking.
Using that aluminum skew gear in place of a bronze gear will result in a VERY premature failure of the part, AND the adjacent running gears. That is not a good repair for the return on the time.
IF they know how to do it right in the first place, then why not DO IT RIGHT? If they don't know how to do it right, then why crow about this video? Either way, the part is far sub-standard and it is the weak link in the gear train which can cause total failure of the entire train of gear driven shafts.
There is a point where "cheap" no matter how costly a proper part costs, is not cheap at all, but costs multiple values in dollar amounts.
Do it right the first time and get the job done properly, even if it costs the equipment owner from putting more dingle balls and fancy painting on their vehicles. (Have you seen the decorations on their hauling and excavation equipment? Save that artwork money and do a proper job of repairs.) I know! That sounds mean. It is economics!
@@dcw56 Agree 💯 that part will break... No other way around it... Cheap material
@@dcw56 Surely the intention here is to make a mould? I mean that would make a lot more sense that people who are much more experienced and knowledgeable than [a commenter on TH-cam who pumps up their own ego by pretending to be a lot more of an expert in something that they know nothing about, i.e. you] would know more than you. Even the most basic engineer would understand that an aluminium part would fail almost immediately. On the other hand, trying to directly machine brass would probably be quite difficult. So I imagine, Mr. Expert, that the intention here is to use the aluminium part to create a mould or former into which they will cast a bronze part.
And although I am not a mechanical engineer or a machinist, I have sufficient education to draw this conclusion.
Which suggests that it is you, personally, who is lacking the required education to be an effective participant in this technology driven world.
So go boil an egg.
@@jasonjason5325 Cheap education. I'm talking about yours here.
@@DinoDiniProductions You need to return to school yourself.. learn how to make a proper part...
As a retired tool and die maker, I can not but admire the skills of these men using the most basic of machime tools and cutters.
Couldn’t help but watch 😂brings back memories of when I worked tool and die. Its amazing how much work goes into not only creating the parts for the machine but the parts that make up the machine that makes the parts. I ran a 13 foot tall drill and prepared the largest slab of metal in the shop that makes up that machine. I think it was because they could see how skilled I was. I did all that with out any school. Started in the stamping department back when Eminem went big for low wage and caught on fast. I miss that job.
My dad recently passed away, he was a retired jeweler, he adored and owned a atlas lathe. He would make dice for manual engraving. I missed him so much. Fond memories spending time with him 😔
these are the real working men and good blessed them with a great skill and you have to be very knowledgeable to know exactly how they work
The cool part of this is how he uses the involute cutter (with a tooth missing), the dividing head and the ability of the mill table to pivot to the correct angle for that helical gear. It takes him awhile and patience to get that right. His cutter was fixed on the horizontal shaft so he had to work with that. You can tell he is not centered on the work piece because he uses the y axis handle and pivot point to keep dialing it in as he travels through the part. Once he has the tool path right he can go back to the dividing head and set it at zero(start point). What if he didn't have a sample part? I give him credit for his use of what he has to work with and getting the job done. Old school machinists are hard to find these days. They work with what they have and do the best they can with it.
A hass 6 axis would have this done in minutes
@@UNcommonSenseAUS I wonder how much it would cost for that Hass machine plus operator for those few minutes, versus these guys for presumably a whole day. I bet its close, but maybe there's a question about availability of such machines wherever this is (Pakistan, at a guess).
I don't think he was travelling through the part, he was just cutting vertically as it is a worm gear.
@@fartingfury about £40-60 a hour but you have setup time aswell to account for, it will certainly take a good few hours for a modern machine shop to machine this component especially since they have no drawings to work back from.
A no way is the operator of a 6th axis haas just gonna push the green button a come back when the cycle is finished, you have to prove out your new program on single block and that takes time itself. If the tools cut quicker than hhs cutters uses in this video then that's because its carbide and is expensive as hell adding to costs!
A naive comment to say a haas will do it in only few mins!🤦♂️
Mating worm if it’s a multi start it will have a large jump and fixed center distance it will bind up.Bronze is the material that must be used aluminum will wear out in a instant.
I started watching this video with high hopes. I've been a machinist for over 40 years. Owned my own shop for almost 20 now. Worm gears are made from bronze for a reason. If you've ever machined it you'll understand. It can be tough but not brittle. The replacement he made is an oversized paper weight if he is using aluminum, which is what it appears to be. If it doesn't fail right away, it may keep you up and running as long as the correct replacement arrives soon. But now you've spent your money twice for the part and twice for the repair time.... I'm seeing the number of views this video has and thinking wow.
Its down to economics. The part was made from the money they got and probably thats all a person repairing it could afford.
@@soni204 Sheer stupidity then. Buy a cheap grade of steel like 1018 or 12L14. It's cheap and you can oil quench without spending the money for heat treating. At least then you have a chance with the new part. It will take longer to machine but won't fail right away. There is NO chance with the aluminum and to say "what they can afford" is just ridiculous.
@@sndnmytrnks I am a tool and die maker with My own cnc shop. You cannot check precision bores with an beat up caliper. For all those who think this is great work, Wait till the customer tries to fit it to the the shaft and its just a few thousandths small, then what? and i think thats cast aluminum. You couldnt pick a worse material for longevity
Does anyone else think this guy needs some safety glasses on?
Came here to say the same thing about the aluminum
I love watching skilled machinist at work. Good job!
so y u watching this then
It´s wonderful to see that human talent can compensate for the lack of automation and obtain a great result. All my admiration for these people.
That gear would be as useful as a chocolate tea pot
@@deeferdownunder Aluminum - I was thinking the same thing.
@@deeferdownunder Aluminum can be hard anodized, and with proper lubrication and light service it might last longer than you would think. No where near bronze, but maybe they could not get the bronze material for an extended time.
Alu would probably be fine. It is not a worm drive.
clearly u dont understand what anodized does
In Japan, old master craftsmen are sometimes conferred the title "National Treasure". I am 73. I have skills it took a lifetime to master.
In the country Chile did that to, is called 'alive human treasure'
And guess what: Don't even think about retiring in the US. - I never worked so hard since I retired. The wokies convinced the kids they had to go to collage for 10 years and get advanced degrees in tings like urban studies and diversity. They ridiculed anybody who wanted to get into the skilled trades - Now there is nobody to replace us (And trust me, CNC is NOT the answer to everything, ) Now us old timers keep getting offers we can[t refuse to come in and do a job or repair a machine because we are the onoy ones that can get the jon done,,,,,but we are dying off ann when we are gone, the skills will be gone with us.
@@mathewmolk2089 I'm a US citizen and retired. I was a fine art photography and art teacher in a public school. I worked for 21 years in NY, which provided a pension of about $2200 a month That, together with our Social Security checks, and sales of a few pictures gives us about $5000 a month, which is enough to pay the mortgage on our new house, which we put 50% toward. Anyway, we have fully paid health insurance courtesy of the school district too, no debt, and are getting by. The pension was a life saver. At the end of my career, I told every kid who would listen, to go for a job with a pension. Most didn't listen and wanted to get rich. They will do what they do. As far as skills being lost. That is a major problem. Someday, many will wake up and think, I'm going back to school to be a machinist, a welder, an electrician, a cabinetmaker, or some other trade that pays very good money because no one is left. That is when there will be a rebirth of trades, but I think it is still far off. Now, they want to be Taylor Swift or some other musical star. She is going to make $600 million just from her concert tour next year. She will become a billionaire. Can you blame them? It won't work out for 99.999% though. then they will have to do something that pays the bills, like me. I was fortunate to have a teaching certificate in addition to my major in art. All the best to you. I do not know what we would do if we only had Social Security. I know it would be a miserable life.
I’m in the same boat. Older machinist looking to retire. I’m not sure my employer will be able to find a replacement for me. I feel guilty. There just aren’t any skilled machinists. I don’t think "woke" had anything to do with it. The unions got busted in the 80’s, all the apprenticeships went with them, and they started sending all the jobs to China. It was all the baby boomers that wanted their kids to go to college. I do prototyping for a company and the young engineers I see now who grew up with 3d printers and went to STEM and STEAM programs are going to do great things. They don’t know shit about machining, but I’ve worked with a lot of engineers that didn’t . I’ve seen kids do projects by themselves that a whole team would be lucky to pull off 20 years ago.
@@mathewmolk2089 It was not the wokies. After WWII, the government made the GI Bill and a college education was within the reach of every person who served. From then on, everyone promoted a college education. Not that it was wrong. Solid statistics showed that a person with a college education earned significantly more than one who did not have one. It is true.And, most parents wanted their kids to go to college. Additionally, many people came here with only a suitcase or the clothes on their back. They worked hard, then sent their kids to college. Some of these kids have become famous, rich, or both. Others have become important writers, composers, musicians, actors, directors, doctors, businessmen, and politicians. Without a college education, and usually more than one degree, you are at a disadvantage in this country. You earned a good living as a machinist, but I bet the guy who was your supervisor and had a degree in mechanical engineering earned a lot more. Never criticize those who have a college education. You only make yourself look dumb. By the way, today it is even nececessary for the local cop to have a degree in criminal justice from the local community college.
I just assumed he used aluminum was either to show off his skill as a machinist, it was going to be used as a casting blank, or as a prototype before machining expensive bronze.
Yes because that break easy it's not harden
It wouldn't work as a patern because it's not oversized to allow for shrinkage, on top of that the shape of the gear teeth would be impossible to remove from the sand.. my guess is it's just a temporary part to keep a factory running until propper material can be sourced
That is what i was thinking when i watched this for a while lol makes sense to me for sure
If you can't respect the person's skills, be it Aluminium or copper or brass, but don't pass negative remarks learn to appericate one's skill, it is his year's of hard work & skill, he had made this Gear.
Unfortunately we are looking at skill applied in ignorance, I live in Africa and it is also common there. It often comes from rote learning where the watcher believes he can do what the watched can without realizing the stuff he hasn't seen is even more important. The knowledge of metallurgy, heat treatment, strengths of materials, lubrication, item design, shock loading, the list is long and all mechanical engineers reading this will know I am not insulting this 70 year old but feel sorrow in my heart that his ignorance in this guise is sadly being perpetuated down further generations. Education from grass root level is essential grow nations.
Very good workmanship. I know it was a lot of work, but, the end product looks really great! My hat is off to such skilled craftsmen.
It's amazing what a skilled craftsman can do even with basic old school equipment!
What kind of equipment do you think builds new equipment. That said the machines you saw in this video is still used daily in machine shops in every country on this planet and still available for purchase new. My point is a very large portion of machine work done in the world today especially 1 off work is done with manual equipment
@@gullreefclub The gear in the video wasn't the crap we see being made today.... no computers... and other technology. Just solid old school machines that last.
Reminds me of the machine shop I worked in around 1972. That might be the same horizontal mill. I saw a shaper in the background. I miss the old manual machines.
He looks very good for a 70yr old, a tribute to his wife.
As an emergency measure I once made a replacement worm gear similar to this in HE30 engineering grade hard aluminium in order to replace a bronze gear that had worn out, the aluminium gear did the job and got us out of a bind but subsequent testing to see how long it would last showed that the wear rate on the aluminium gear was something like 100 times greater that of the original bronze gear and by comparison the wear rate of a bronze gear (NOT BRASS which is a pretty useless material to make skew gears out of) is about 100 greater than a hardened steel pair of gears, proper lubrication being applied in each case
You could also add some nikasil coating on the aluminium as we do it for aluminium motorcycle cylinder blocks, but i don't know if they have access to that technology
@@kukipett An interesting idea, we have hard anodising which prevents wear for a little while but it wears through creating an abrasive paste when the remains of the anodised layer mixes with the lubricant and greatly increases wear. My suggestion is always to use the right material for the job along with the correct heat treatment before and after machining, finish grinding and then lapping and polishing as required. I don't know if the pattern gear in this video is brass or bronze but I will say that brass is a useless material to make a gear of this type where there is a sliding action between the gears, with a rolling action and low torque brass may not be too bad but the correct grade of hard bronze is the vastly better material
That's what I was thinking also, I wasn't sure if it was Alu what they were using as a replacement because it seemed like a massive downgrade from the original.
BUT it's probably what they have to work with because they also used a cutting tool with a broken tooth.
So it might be like sitting on a remote island, having to build a two story house with only a kitchen knife😉
No doubt. This Is a pattern to make brass gears.
You don't make worm wheels out of hardened steel though.
I had a friend who bought a lathe machine but didn't know how to use it , later he became proficient with it and the rest is history! If you have the drive and passion anything is possible!
I recently had a company in Sydney manufacture a very large double throated worm gear for a worm drive differential. The nickel bronze gear was spun cast initially as this creates a much stronger gear. Machining took a week! And it had to mesh perfectly with pinion. Overall 6 months. People don't generally make gears like this any more!
did they also make it out of aluminum for you?
Excellent job, people are praising the old man, and rightly so, But the man who did the set up and machined the blank is equally skilled. Many congratulations from a long retired machinist from Scotland living his last days in Argentina.
👍👍👍👍👍
I think it's amazing how these guys use what we would call primitive technology to make some pretty complex parts. Complements and two thumbs up.
A manual lathe is not primitive. It's old but it's not even antique.
Hello Kevin;
Everything here seems like I am arguing about this vid, but what is thought of as "primitive technology" as you put it is what was used in WW ONE to make parts for machines back then. Those machines still work perfectly if taken care of. The FACT the the guy had to jam a screwdriver into the over arm on that horizontal mill shows they can't even be bothered to make something as simple as a gib. Something I was taught to do with a file back in the 70s when I was still in high school.
There is no mystery or craftsmanship here. This is a video of how to do things all wrong and in a slip shod way.
He knows what someone long ago showed him, but if he had a new horizontal milling machine, I imagine he would wonder where to jam the screwdriver in to take up the slack in the gibs. (Start by adjusting the gibs in the firs place, IOW..)
@@dcw56 primitive technology was the wrong terminology that I used. Basically saying these guys sit on the floor hold parts with their toes and still manage to get the job done. I don't think that crankshaft is going to last forever but they make do with what they've got. I think that's my real point. And it does look pretty primitive but they do get the job done even if it's only a temporary fix.
Wtf the cluelessnes in this comment is amazing
If you think this is primitive technology then maybe look up what sort of machines Rolls Royce uses in their factories.. Rolls Royce is still using the same machines they used back in the 50s and before
These guy are incredible craftsmen! They do it with old world tools. Much respect!
A machinist working in a 6'x6' corrugated shed in Tullos, Louisiana made every spare part needed for drillin' rigs and pumpers in that little one-horse oil-patch town in the 1940's and 1950's. Mr. Stiart (sic) could make anything needed to get the job done.
Yeah, we call it no such thing as cant. If they ever have to bring back the oilfield, I don't know where their going to get the experienced. Gonna tak a wile.
Must have more than one horse, town, the mail delivery probably by horse and carriage too
کاش ان جیسے زبردست ھنرمند لوگوں کو کوئی قدر دان ملے
My dad was a welder by trade but had a lathe in cellar. I too watched him for hours down there on many projects. So I admire very much your skills. The piece you made was a beautiful piece of art.
Dad was a carpenter and was forced to make crazy things, he would have done well working here th-cam.com/video/xnH7ItynPGw/w-d-xo.html
I didn't know a lot of sons following their Dads around like I followed mine, watching and absorbing them do things. 🙂
I was a CNC machinist for years, I love to watch people in different countries make parts or products, with what we consider primitive tools and equipment. We are use to getting our products made in huge factories, with millions of dollars worth of equipment to make the most basic of products. In these 3rd world countries they are making beautiful pots & cooking wares, building parts like this gear on equipment that is ancient by modern standards. These people have the skills and experience to make beautiful, working, and purposeful items, from recycled or raw materials. I know few machinists here in the US that could use that equipment and make the same part, as he does. When you don't have the right tools for the job, you improvise and use what you have and get it done! Hats off to these skilled workers!
A Lathe and Horizontal mill are NOT primitive tools. In a tool and die type shop a customer can bring in a one off job and a tool maker will be in the office typing the invoice before you can be done writing the program and loading the tool changer. CNC is not the answer to everything. In fact there are jobs (like welding up a gear with a couple missing teeth in a bevel gear and machinating them) that are totally impossible on a CNC machine. The Lathe and Bridgport can still get the job done. The only place the cost of a CNC machine can be justified is when you are turning out multiple parts. On onsie-Twosies CNC will never pay for itself,,,,and most of the time is actually slower then manual machines when they are in the hands of a skilled machine hand. ,,,,,, Hell 90 percent of CNC operators cannot even re-grind a drill bit.
That was absolutely amazing 🙂 Hardcore men there,no eye protection,no gloves,hardly any lube at all. I know it's not highspeed cutting.
it's dangerous to wear gloves or long sleeves the machine will suck you in.
@@edmundooliver7584 About 50 years ago, I saw a young apprentice guy get his long hair caught in the chuck of a drill press. It wasn't a pretty sight. Not much emphasis on safety back then.
90% of people in the world working like that.
Working around that type of equipment it's best not to use gloves or wear loose fitting clothes. Which both applies to these artists. I worked in a boilermaker shop for years and saw the result of a fellow getting a glove caught while use a large drill press.
No hugo boss suit with neck tie and hard price 'crocodile' italian shoe..
Bravo .
You are great . We need people like you in Africa
Considering the equipment he had to do this job with, I think he did an admirable job indeed. I’m no machinist but my Father was and I got to watch him use various pieces of metal working machinery growing up. This man had a cutting tool that was on a shaft that wasn’t true and it had a screwdriver jammed in to keep it from moving. No safety equipment whatsoever. At 70 years of age he’s lucky to have his eyesight.
He jammed the screwdriver in to lock the arbor support in place, instead of tightening the bolt.....
The shaft actually is true. Watch again, that final spacer is off-center (cam) ground on the OD. If the shaft wasn't true you'd see the machine either lock up or dance around (from vibration).
I'm 76 and just now started to wear glasses. I didn'[t need them either when I was a kid of only 70.
@@mathewmolk2089 I don't think he meant age related vision loss, more like tool disassembly related, lol
Whoever these guys are they are an asset to their country.
If giving these people a few more machines they will produce mighty engineering companies
Interestingly enough, the old Gamewell type municipal fire alarm boxes had a clock spring powered gear train like a clock, made of solid bronze they had a different feature from clocks- a bronze disk about 1 to 1-1/4" diameter with teeth on them that resemble gears, but they aren't gears, they are notched in a way to create a numbered code based on the number of teeth and their pattern of gaps, as it turned when the alarm was actuated, a set of contacts rode on the teeth and gaps which sent a DC signal out. The remarkable thing was every one of these code wheels was unique and one of a kind because a large city might have several hundred units or more and they each had to have a unique number, so it wasn't like they could set up a machine and make 500 identical code wheels and spread the costs of the setup etc over 500 pieces.
Also, I have a set of blueprints the city provided machinists in the 1930s to make these, even the angle and width of the teeth varied depending on a few things such as how many teeth had to be cut on it and leave room for gaps, a box having a number like 9799 had to have different teeth than one that had say the number 322 since the diameter of the code wheel was limited and couldnt be made larger and still fit the mechanism.
After watching the video I must declare that, Sir, you are a master at your craft.... Awesome.......!
1st rule of turning: do not get your hands/fingers anywhere near the piece while it is turning.
2nd rules of turning: do not leave any tools that can fall while the piece is turning.
3rd rule of turning: short or tight long sleeves when working with a lathe.
4th rule of turning (or machining in general): wear closed toe safety shoes.
@@jefffrodermann5348 5th rule: wear safety glasses
This is somewhere like Pakistan where they where long sleeves and sandals
He has his sleeves rolled up, and he is 70 years old , old enough to have years of experience doing this his way
The old man's beard looked very scary close to that turning shaft!
All without fancy expensive machines and computers. Nice work.
This is something that is done hundreds if not thousands of times a day all over the world! His machining is anything but precise but he made it work! Any low level machinist in the US would have easily turned out this quality work or higher pre WW1. I was taught to hob gears in high school machine shop, in college/apprenticeship we went far beyond that! I suppose it seems amazing for those that know nothing about manufacturing!
You, sir, seem to understand. What that guy did is not magic. It is not hard to do. It is not even high school shop class quality on any kind of manual machine.
For some reason, the folks who aren't actual manual machinists, (of which there are tens of thousands still in the United States) seem to think this is some king of magic. The man knows how to do what he was taught, but it is still hack work, and the video description makes it out to be some kind of miracle. It is common work in most other countries.
I couldn't help laughing as he was using chalk while pushing the sector arms out of the way. If these guys had a little bit more knowledge they could do much better.
@@dcw56 Precisely
@@rotax636nut5
Thank you, sir. I did not mean to tell people that this guy was not good at what he knew, but what he knows is the same thing European and American machinists knew over 120 years ago.
People thought I was being mean towards this man cutting that (sorry, but poorly done) gear. It is nothing unusual, even for a guy like me who has worked in an ALL MANUAL machine shop for decades. Yeah, I'm an ol' fart.
Our Almighty God and Savior bless him though! He probably has a kind of hard life. But his machining is no miracle and not even good enough to be admired. I'm glad for him that he has a job, and hopefully brings home the bacon to his family.
@@dcw56 When OSHA and EPA and NAFTA came in and the commie teacher's unions got the schools to replace industrial arts with diversity and urban studies classes it signaled the end of the skilled trades in the US ,,,,, Take a look at 30 year old American men. - They can't do ANYTHING. They don't even know how to change the oil in their car much less be able to set up a universal mill (which is not rocket science) The average American male is a totally helpless subject of the nanny state. Take away their smart phone and they can't even find their way to a gas station.
It’s interesting to watch these highly skilled craftsmen working with such antiquated machinery. I have nothing but admiration for them. But I would really like to see some of these parts fitted and doing the job as intended. I think that would be a satisfying video to watch.
I've got an almost identical set up as that mill in my workshop except its a Richmond (midgley and sutcliffe). Might even be a bit older. 1930's ish. With a Cincinnati dividing head. Runs great.
Thank you old man don't worry im older than you your job is perfect and very hard i wish god help you too much ,
As a machinist I cannot believe the stuff you guys do were so little just amazing stuff!!!!
Wow I’ve been a toolmaker for decades but admire your skills.
I've always regretted not continuing to learn to be a machinist. I had an older friend that owned a machine shop and constantly offered me the chance to learn the trade from him. But the down side that caused me to lose interest was his son while using the lathe the piece came loose and hit him in the head. He was mentally and physically never the same.
I'm sorry about that young man getting injured. That is not the fault of the machine, but the machinist. It is too bad that he had not been properly trained in the trade.
Machinist is the best of trades. You can make anything except what a tool and die maker can do, but what they do is extremely specialized. Machinists can do almost anything if properly trained. It truly is the best of trades.
@@dcw56 I don't care how trained you are (which is only a minor prerequisite to experience) mishaps are going to happen and you can even get killed. "Safe" is only a word in a machine, wood, or fab shop. Every machine in there wants to take a chunk out of you and ruin you day. If you work there long enough sooner or later one of them will get you. The only question is when, and how bad. It's shall we say "Cast in Iron" -(Steel mills and foundrys are great places to get hurt too.) There is no such thing as a totally safe workplace, Or anywhere else for that matter.
@@mathewmolk2089 How long have you been a real machinist? I don't mean a CNC button pusher, but a REAL machinist?
I'm near 67 and still have my head, my butt, two full arms and two full legs along with 10 fingers on my hands and 10 toes on my feet.
I will not accept that this guy did a good job just because the parts match well enough. They have to match perfectly, or you have a very short working life for the parts.
See what these "trained" monkeys say when the part comes back in a year. "We make a new one, just like last time..."
Unless you are a REAL machinist, stifle it, please. BTW, I made 42,000 parts in my machine shop since January 2020. No injuries
Properly trained. Properly vetted. Properly aware of machines turning 30 pound work pieces. Proper!
@@mathewmolk2089 All i can tell you is 67 years and still have all my parts. I was trained right, and I bless the men who trained me!
back in the war, our parents had to grow potatoes..it was 1941... i remember one morning...blah blah
Wow! My best friend, Nice one video. Love for you also best wishes to you, Carry on dear.
What a fantastic job he did. Any Western machine shop would be delighted to have him. We have this perception that these are back street workshop chancers because of where they come from, but forget that they may be just as qualified as any. Fair play to them. I love the way the screwdriver is jammed in! Well done.👍☘️
Yes I thought the wedge "screwdriver" was a humorous touch. 😄👍
@donalfinn
Thank you!
Being a German Geologist, I've spend decades in ""under developed"" countries.
Our western arrogance towards those people never ceases to amaze me!
Countless times we needed spare parts, to be ship in and worth thousands of dollars.
And then, bingo....a local mechanical , or electrical workshop produced a replica, even better than the original.
For a handful of dollars....and a pad on the shoulder....how patronizing and unfair?
Just because people are poor, and so are their countries....does not mean they are dumb and stupid!!!
I have seen cars and trucks rebuilt....very, very few western workshops would be capable of doing that.
As for the screwdriver....that is the essence....improvising.....and it works!
Cheers
Always thumb up for the people that work. But the cameraman not show the most important moment - the smile of the man when the job is finished
He is a very skilled machinist, but he should have some eye protection from splinters and swarf. His beard was dangerously close to getting caught in that milling arbour!
very skilled? you must be both ignorant and high
Wow, I will always cheer for you in Korea I'm looking forward to a great video. Have a nice day.
I have to say some people's ability is not just amazing. There is barely words to describe their ability. To machine this, is one such case. All he used were micrometers and a lathe, little else. His skill, acuracy and expertise is such, few could match.
dude youre insane
these guys are true craftsmen and artists.. no computer driven machines, no CAD...!
They may need to set some mouse traps, I hear a bunch gathered around the microphone!! Great Job!
These guys could build anything, the real A-team
The original gear is made from brass for a reason. I’m not sure aluminum would last long. Also, the one they are copying looks fine. Maybe the one they are replacing was destroyed. It is awesome that someone could make this. It’s an impressive skill.
The original gear-wheel is made from bronze to be able to withstand loads and wear & tear. It is usually driven by a hardened steel 'worm-gear'. I am familiar with these types of bronze gears. They are designed for lots of abuse. The aluminum replication will not hold up very long under load.
@@robertducanis4448 They use aluminium ones for casting formers.
@@patverum9051 if you mean they want it for a patern to mold the casting sand then no, it would have to be made oversized to allow for shrinkage and this wasn't oversized
Do you mean steel?
@@ThomasATorr the original gear was bronze, he is using aluminum. It won’t last long in this application. They are brass for a reason.
Good to watch a craftsman. Doing his work.
I worked for a German company . And we made a lot of unusual. Parts. But as technology grows . Finally they put in CNN machines. And even this they did great work. , true craftsmanship. Was lost.
I love the jammed screwdriver to lock the support
That was the best😂
Gibbs very badly worn.
These craftsmen make the best use of available tools and what they have learnt.
I am impressed not only by the skill but also the invisible safety glasses and beard protector.
They have EYEWARD CHIP Deflector instead of common safety glasses.
don't forget the open-toe safety sandles
See what can be done with OSHA out of the way. lol
Truly amazing that with all the techniques and modern technology Alvin and the chipmunks still get a part.
Im a 37 year machinist and its great to see a good product made under these conditions. The screwdriver used to jam the arbor rest in place is still tripping me out. But how many people were expecting him to get his beard caught in that spinning arbor nut? You know its had to happen to somebody at some point.
the screwdriver, i laughed out loud! glad someone else caught that 😂
Beard, too close to stuff, no safety glasses, sandals, loose clothing. What could go wrong?😂
The shear skills of these people are amazing.
I was a "real" machinist.. spent 15yrs doing automotve prototype development -- this man still has his ""skills"" -- forgotten art right there..
This sounds like sarcasm, but I’m getting what you mean.
السلام عليكم ورحمة الله تعالى وبركاته عليكم إخواني في الله ماشاء الله عليكم الله يحفظكم ايعطكم الصحة والعافية يارب العالمين. فنانين الحمد لله 👍👍👍👍👍🙏
Wonderful & Skillful Effort should have been prepared in the Original Material Like Brass or Bronze.
Esto es lo que se llama conocimiento y habilidad manual, cosas que se han ido perdiendo con la automatización. Es un trabajo admirable, y logrado con máquinas herramientas que dependen de la pericia del operador para lograr un trabajo perfecto. Felicitaciones.
AS a machinist seeing the arbor support held in place with a screwdriver made me scared.
Súper. No se varan y, hacen que una máquina o equipo de gran valor no se detenga y dañe. Mucho ingenio y Dios los siga bendiciendo.
I like the arbor support lock at 10:17.
The ways on the machine are probably so worn that the original clamp won't lock. Some arbor with a dogleg and think only a couple teeth on the cutter were actually doing the cutting.
Pretty sure if you have a look at the cutter when they are fitting it ,it is missing a complete tooth!.
Outstanding, there is so much knowledge and skills inside of people that need to be past down to the young
Make a gear out of alminium, last 3 sekunds i think :) But they have a garanty on the part expires when out of their shop, hopeless
You took it from my tonque!
Bullshite title, probably ripped from elsewhere. But strange they should make it in alli are you sure its alli? Original looks like bronze.
There's always an endless list of you clowns repeating the same criticising comments over and over again like a bunch of mindless parrots all thinking someone cares.
Excellent work specially from these old machines I gave 5 out of 5
Ola ! Muito difícil, mas vocês dominam a técnica, e sao excelentes profissionais. Vi que um milímetro de diferença nao funciona como deve. .vejo vocês muito atentos a isso. As medidas. Muito bem. Gostei. Deus te de muota saúde. Abraço do Brasil.
Experience is mighter then sword, you are very good skilled workers. Very good technical hand. God is very great .
These guys are amazing in what they do and have to work with.
no not really
My dad's 99 years old still running his machine shop still making parts been doing it for a long time excellent I think he's a genius he's also learned how to transition to CNC machines as well as old school.
Guy is a legend
Barney
I Love these guys and those with similar skill. They can look at what's needed and the intended purpose and produce it. CNCs etc are tremendous but the basic ability to see what's there and what's needed and produce it so it works undercuts everything else. Made me think of our social and political problems and situations lacking the basic real physical world and natural laws that the same as building and bridge have to have the basics of mathematics and engineering to work. We do live and operate in a physical world. Deep Huh !
Can't substitute aluminum for bronze. The newly manufactured gear is of little to no use when installed in the original machine. It makes a nice novelty paperweight or door stopper instead.
There is only 1 problem with the Aluminum gear he made... If it as to replace the brass gear they used as a template, the Aluminum gear will not last as long as the brass gear would and it will probably fail prematurely on whatever worm gear is driving it Aluminum is very soft and can bend way easier that Brass. So whatever machine it would be put in will not last as long as the Brass gear would. just saying. Gears also need to adhere to tolerances down to the thousands of an inch (.001) if not the worm gear driving the Aluminum gear will wear much quicker. As for the skills i give him mad props on doing machining that way but the machine will suffer if it isn't in specs don to a (.001) of an inch.
Man, the chatter marks in the gear gullets are off more than a thou. Didja see that gear cutter bouncing up and down?
Your right, but as a qualified technician in mechanical engineering I will say that both aluminium and brass are both highly unsuitable materials to make this gear from, the material should be either C90700 (SAE65) bronze or S45C carbon steel which will need to be heat treated, checked for dimensions, possible finish ground then lapped to the correct surface finish/texture on the gear teeth before use. With all these videos that demonstrate 'amazing skills' it's not enough just to be able to manufacture the item, the product also needs to be made of the right material in the right machinable condition in the first instance, then heat treated and ground as required then polished and/or lapped before it will be suitable for reliable use. This is why OE gears and parts in general are expensive and why these well meaning and skilled artisans working in sheds with dirt floors are cheap. No disrespect to these guys they are very clever but lets not make them up into something they are not..
Yes yes no disrespect here either I was a macinists for 12 years. I was just stating facts about tolerances and material used. :D
@@rotax636nut5 If they get a years use of that gear they'll be happy.
@@rotax636nut5
As a machinist at the trade for decades, I do not think these guys are either "clever" nor (at all) artisans. I do not mean to demean them. They are doing what they have been taught, and seemingly have not progressed for three to four generations. Still doing the same ol' thing to make something work for a little while longer. That is NOT what a real machinist does. We make parts that are at least as good as the original spec, and yes, sometimes that means sending it out for heat treating.
Skipping steps because of ignorance or price does not make one an artisan, (I am not an artisan. I'm a machinist, manual machines only) nor does it make you a machinist, or even clever.
I understand that these guys may be just working to make enough to eat, but that does not make them an artisan any more than a guy who grows corn or a man who catches fish for market. Using clapped out machines and getting things "good enough" by eyeball does not a machinist make. Fixing the old machine would be a good first step in becoming a machinist. I do understand he needs to eat, though, but that lathe in the shop is only about 10 years old... The money for it came from somewhere. It is not an old machine. The old Adcock, Now that is an old machine. Fix it!
I remember in my apprenticeship days (1963) using this machine technology. Great skill is required. I doubt the young fella doesn't even know what a manual dividing head is. These guys are great artisans in my book.
You only have to look at him to tell he knows his stuff, a true machinist engineer
A good Job well done Lad's. Have a great Day.
Amazing skills with a machine that has everything mechanical. Amazing! We don't have skilled workers any more. Great work.
They make the Space X with unskilled workers do they ?
We don't have skilled workers any more ? Maybe in your sad circles! 😂
Yes we do. I am one sitting in my Lazy Boy looking at my retirement. Sadly the pay rate for Machinists has gone way down in relation for the skill level required. When you can go to McDonald's and make 75% of what a machinist makes, sort of takes the desire out of staying in the trade.
It amazes me how alvin and the chipmunks make things properly by hand,bring back the the skilled workers and I know cnc machining is brilliant but I don't think you can beat a hand made item.passion.i hope the videos money goes back to the makers and not in someone else's pocket
HAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHA i was looking for someone to see if they'd mention chipmunks, you beat me to the punch 😁
These men don't have sophisticated tools and machines yet they make the part just like the original one ..
My guess, from the looks of the shop, they got about $99 for it plus materials. That piece would cost $10,000 here and you would be lucky to get it in a month.
Yes because $99 is all that the customer can afford and he needs the part to work and feed his family ... no one else will feed the families of either party.
@@camiemengineer I don't doubt it and I am not judging him. It is a shame he probably cannot charge more. He has very high skills.
@@russmartin4189 Yes, very true -- I agree with you.
This 70 years man very talented .This type people should live in Bharat.God may bless him and give more health
They don't need to worry about thermal expansion of the part - since no matter how hot it gets from the cutting operation, it'll ALWAYS be hotter outside in that part of the world anyhow! :D
Excellent observation and relavant comment.😊
No calculation ,no chart ,no nothing just experience ?
You must give it to them ,well done guys 👍🌺
Did you not see the micrometers? The gear cutter gauge they marked? It was all measured and calculated.
@@Jon-vm3qw using the micrometer come as a calculation ??!
There are many machinist work like that ,they need a model and they making exactly the same , without using any charts or any calculation !
Didn't you see how they move the table for a angle of gear ??
Nice work with limited tools. BUT that gear or its mating part will last a very short time. The original was made of brass/bronze for a specific reason. Building up the worn item by brazing and then remachining would give a much better product. regards
Correct..!!
Yes I agree the worm mating with that gear will wear out in no time!!! I am talking from 55 years experience in machining such things, that material should be manganese bronze or at least aluminium bronze mating steel with steel is a joke!!!
Incredibile....... questa è alta scuola di matematica. I miei più sinceri complimenti. Mai avevo visto niente di simile. Saluti da Torino Italia
Masterful at what they do but I don’t think I saw anyone that was 70 years old.
The guy with the white beard would be very close, if not already.
@@timothygeiger8271 äaAaaa
@@SIRafiq so, in all your infinite wisdom is a "yaer"??
Good good job, Old School Technology still works just fine!
i went to a city collage for 32 years to have access to a machine shop and did lot of things like this it was a blast . sad thing is most would just open there wallet but the day is coming were that won't do and its coming soon so learn something real
Excellent job ! 👍
Man's got skills 👏👏
Takes me right back 55 years to my apprenticeship days. Brilliant.
40 years for me also.
you apprenticed with a bunch of pakistanis?
Making the gear was interesting and remarkable. But what was really astounding is the machinist didn't look a day over 50, even with the grey beard. (Look at the lack of creases at the corner of the eyes.)
He is not 70 that's for sure!!! 😀
@@henryrollins9177 max 55
safety glasses and a beard retainer is what makes a machinist get old