Well done Rusti, something from nothing again, and what perseverance!!! All the odds stacked against you but you just keep battling through, fantastic job. Cheers, Jon
I enjoy your approach to solving problems. Not many people would plug and weld an old plate, then endure the ear splitting ringing of machining it true! (I've been there). Great stuff 👍
Nice job Michel. Making gears always seems like rocket science but if it doesn't need to spin really fast or transmit heavy loads a filed tooth here and there works fine.
G'day Rusty. I thought a mig welder would have filled in the holes quite well. The setup, machining etc was really well done. Just goes to show how much you really know 😊. Wifey likes your sence of Humour as well. Overall a great teaching video. Waiting for the original job to go through
Hi Michel ☺ well your ingenuity strikes again, lol, what a great way to make a gear blank out of scrap, ok you had a glitch when the cutter broke, but at least you only had two teeth to file, and it works. This is what hobby engineering is all about, adapt something , or make a tool to get a problem solved, and carry on whith the project, that's what makes it fun and interesting. Thanks for another great video mate, stay safe, best wishe's to you and your's, Stuart UK.
It's always the last damn cut. I ruined a pair of long t-nuts yesterday, on the last cut. Was hurrying, because I had to get back to work. Bah. Nice work, it's good to see scrap turned bak into useful items.
Hi Michel, great video I had absolutely no doubt you would solve all the problems that came your way .... solving that puzzle though might be even beyond you😅😅. Have a great weekend
Well done Michel, Im sure that will help with your threading requirements in the future. It does not matter how you get to the finish line, even if it was with a file...
Have you seen the 2 button method for making gear cutters? Sounds very interesting .... If the straight cutting tool on the shaper fits... Why not to install the rotary table on the shaper? I thing this will work to
Given that you determined that you could use a straight-side tooth form for the 80T gear, an alternative would be to mount your dividing head on the shaper - no need for the involute generation that you gear copying setup uses. Of course, this would require another segue to make a dividing head mount for the shaper... :-) Your approach works fine - just suggesting another way to approach the problem.
The tooth forces on those gears are quite low, especially on larger gears. A piece of aluminium plate would be easier to work and plenty strong enough, even a piece of 10mm thick acrylic (perspex) makes a surprisingly sturdy gear. I know machinist guys dont trust plastic very much but it can be a great easy solution for something that is only used on some occasions. 👍
@@Rustinox .. hi, is there a metal scrapyard near you? There are a couple near me, they have literally shelves full of metal offcuts from manufacturing, like 10mm and 12mm aluminium plate, round bar offcuts in various steels and aluminium alloys etc, all sold dirt cheap around the scrap recyling price. Most of it scratched etc but otherwise good, even with the alloy markings code on it. Cheap as chips! 👍🙂
Michael, I'm absolutely amazed that you have any hair left. Youre obviously mot related to Murphy and his crazy laws. But! Just maybe you have a Belgian equivalent to Murphy and his laws. Either way, well done on the mental/metal gymnastics needed to produce your gear out of the junk drawer. Others would have given up. Hopefully your 80 tooth gear will produce what you need. Regards from Canada's banana belt. 🇨🇦🍌🥋🤞🇨🇦🕊️🇺🇦🕊️🇺🇲👍
Good video. The problem with tables with their filled in rows and columns in all its formality is that they give the appearance of being sacrosanct. Now I wonder how unique is that periodic table of the elements.......lol.
A quick second comment regarding your gear ratios, though. Your 2mm pitch gear setting is an abcd (4 gear) setup. If your gear setup plate was calling for (for example) 72 - 100 - 80, you could ignore the middle gear entirely and your gear calculations 50 seconds in would be correct. However, assuming I'm reading the gear plate correctly (8:38 in your original video), they're calling for 40 - 80 - 72 - 36. The 80 and 72 tooth gears are locked on the same axle, so you have 2 gear ratios to worry about. The first, from input to the driven pair, is 40-80, or 1-2. Assuming 1000 rpm at the input, the driven gears run at 500 rpm. Then from the driven gear to the output you have 72-36, or 2-1. So, again assuming 1000 rpm at the input, the 500 rpm at the driven gear becomes 1000 rpm again at the output. As a side note, it's not surprising that the ratio is an integer for a metric machine cutting metric threads. Look at the odd ratios you have when cutting imperial stuff :) So you could replace either of the 2-1 gear pairs with another pair of the same 2-1 ratio, and you could cut your 2mm pitch. Or you could replace the whole thing with a 3 gear setup where the input and output gears are the same if you have 2 identical gears available. Say 60-72-60. That would work too and might well fit. I suggested a 30-60-72-36 setup because the sizes were close enough to be likely to fit, and because your gear plate shows a 30 gear setup being possible on gear 1 (which is often tricky, as it's the spindle gear). This latter point is moot as in your case the 1 gear appears to be the exit of the gearbox, I hadn't seen that. Give it a try. Not that I'm suggesting cutting an 80 tooth gear is in any way a waste of time - it appears to be useful elsewhere, it means ou can use your gear cutting plate without worrying about "oh no, I have to do this instead", and gear cutting is always good therapy.
@@Rustinox Thanks. If you wanted to bootstrap the missing disks for your dividing head, it might also be possible. Drop me a line, I can maybe come up with a plan based on what you have.
Great video Michel, I think I enjoy gear cutting as much as single point threading. When I cut gears I use a boring bar with a hand ground HSS cutter held by set screws. and usually I work with aluminum or brass. Enjoyed, cheers!
You and your workshop are like Rumpelstiltskin’s spinning wheel, you can turn straw into gold! Thanks for another great video Michel 👍 🇬🇧
Lol, it's not real gold but it's fun to do.
Once again you have won the fight. Forgetting to move the tool is a hazard that I have experienced myself. Thanks for the video keep on keeping on.
Thanks Harold. Breabing tools is always a bit stupid.
great video production/discussions/demonstrations/build….enjoyed
Thanks.
Making do with imperfect materials and imperfect tools is a real skill that you have mastered. Great result!
Thanks Craig.
Well done Rusti, something from nothing again, and what perseverance!!! All the odds stacked against you but you just keep battling through, fantastic job. Cheers, Jon
my thoughts exactly, Jon!
Things get much easier from the moment you stop taking it seriously :)
@@Rustinox lol, so true, a valuable lesson indeed!!
Enjoyed your gear cutting adventure, Rusti👍! I’m so pleased the collet can be useful. As for the puzzle, well, good luck - it’s many pages 😁
Thanks again, Dudley. And the puzzle is almost finished... well, not really :)
Never doubted you for a minute , that you would come up with some sort of scheme to make it happen ! 👍
Lol. Thanks Max.
Nice gear Rusty. Good thing we did not have to watch you file 80 teeth.
I think I would have find another solution.
Well done. Making something is not a question of having all the tools, but to use what you have to make what you need.
Spot on. And go for it.
I enjoy your approach to solving problems. Not many people would plug and weld an old plate, then endure the ear splitting ringing of machining it true! (I've been there). Great stuff 👍
Well, It wasn't that bad. It worked just fine.
eyup Michel
Magic something from nothing again, just my "cup of tea"!!😉😉👍👍
ATB
Kev
Thanks Kev.
Nice job Michel. Making gears always seems like rocket science but if it doesn't need to spin really fast or transmit heavy loads a filed tooth here and there works fine.
I think so too. This is a very slow running gear and will be used maybe twice a year. So...
The Dividing Head has really been a big plus in your shop, I hope one day to have one as well (@@)! Scrap turned into a Gem, got love it.
Thanks Bear. I'm sure you will find one some day.
G'day Rusty. I thought a mig welder would have filled in the holes quite well. The setup, machining etc was really well done. Just goes to show how much you really know 😊. Wifey likes your sence of Humour as well. Overall a great teaching video. Waiting for the original job to go through
Thanks Ted. The holes are 16mm. It was easier to make plugs than to fill them all with weld, witch could also pull the whole thing out of shape.
I'm glad you were able to get your collet.
Yep, me too.
I had to make one thread with imperial pitch. I just 3-D printed the gear. It worked very well.
Sure, it works very well.
But I don't have a 3D-printer :)
@@Rustinox Mine has broken down. So i installed an ELS on the lathe. :-)
Excellent work Michael! I really enjoyed watching you work through the challenge of choosing and making your 80 tooth gear. Very nice editing too!
Thanks Allen.
4 plugs? Why not just plug one hole and offset the template to clear the other 3 holes?
That's also possible. For me it was just easier to keep it more or less in centre.
Hi Michel ☺ well your ingenuity strikes again, lol, what a great way to make a gear blank out of scrap, ok you had a glitch when the cutter broke, but at least you only had two teeth to file, and it works. This is what hobby engineering is all about, adapt something , or make a tool to get a problem solved, and carry on whith the project, that's what makes it fun and interesting. Thanks for another great video mate, stay safe, best wishe's to you and your's, Stuart UK.
Indeed, it worked. Thanks Stuart.
It's always the last damn cut. I ruined a pair of long t-nuts yesterday, on the last cut. Was hurrying, because I had to get back to work. Bah.
Nice work, it's good to see scrap turned bak into useful items.
A bit frustrating, but s**t happens.
That turned out well Rusti. Good video.
Regards.
Steve.
Thanks Steve.
fantastic result and well thought out,, congrats!😀👍👍
Thanks.
Congrats the journey is sometimes longer than expected.
Absolutely.
well done Michelle
Thanks Kimber.
A lot of work but a big addition to the capability of your lathe. 2mm pitch is very common. Cheers
Thanks Paul. It seems to work just fine.
Getting it done like none other! Wow, this series is very intersting, TY!
Thanks.
U r great 2 watch and learn from. U have a great delivery style.
Thanks.
Hi Michel. That was great, well done.
Thanks.
Wow I love how you make things work one way or another to get the job done it so awesome
Thanks. Just go for it :)
It would appear your project fought back as well, nice outcome in the end 👍
Indeed, it did. All this just to cut one thread.
Thanks for sharing.
My pleasure.
You slayed the dragon. Nice job.
Thanks, it was just a small dragon :)
Hi Michel, great video I had absolutely no doubt you would solve all the problems that came your way .... solving that puzzle though might be even beyond you😅😅.
Have a great weekend
Puzzle is almost finished... well, not really :)
Another success mon ami. 👍🏻👍🏻👍🏻 Gilles
Thanks Gilles.
Well done Michel, Im sure that will help with your threading requirements in the future. It does not matter how you get to the finish line, even if it was with a file...
You're right. Just do it.
Have you seen the 2 button method for making gear cutters?
Sounds very interesting ....
If the straight cutting tool on the shaper fits... Why not to install the rotary table on the shaper?
I thing this will work to
The dividing head is bigger than the shaper table, so that's not an option.
Thanks........again........inspiring
Thanks Niel.
Well done mate 😊
Thanks.
Wish i could suck coolant off my milling table when cutting gears. Amazing!
I'm sure you will find a way. Maybe with a venturi system?
Given that you determined that you could use a straight-side tooth form for the 80T gear, an alternative would be to mount your dividing head on the shaper - no need for the involute generation that you gear copying setup uses. Of course, this would require another segue to make a dividing head mount for the shaper... :-)
Your approach works fine - just suggesting another way to approach the problem.
The problem is that the dividing head is bigger than the shaper table.
good video rustinox
Thanks.
The tooth forces on those gears are quite low, especially on larger gears.
A piece of aluminium plate would be easier to work and plenty strong enough, even a piece of 10mm thick acrylic (perspex) makes a surprisingly sturdy gear.
I know machinist guys dont trust plastic very much but it can be a great easy solution for something that is only used on some occasions. 👍
You're right. But all I had was this steel plate.
@@Rustinox .. hi, is there a metal scrapyard near you?
There are a couple near me, they have literally shelves full of metal offcuts from manufacturing, like 10mm and 12mm aluminium plate, round bar offcuts in various steels and aluminium alloys etc, all sold dirt cheap around the scrap recyling price.
Most of it scratched etc but otherwise good, even with the alloy markings code on it. Cheap as chips! 👍🙂
Michael, I'm absolutely amazed that you have any hair left. Youre obviously mot related to Murphy and his crazy laws. But! Just maybe you have a Belgian equivalent to Murphy and his laws. Either way, well done on the mental/metal gymnastics needed to produce your gear out of the junk drawer. Others would have given up. Hopefully your 80 tooth gear will produce what you need. Regards from Canada's banana belt.
🇨🇦🍌🥋🤞🇨🇦🕊️🇺🇦🕊️🇺🇲👍
Things get much easier from the moment you stop taking it seriously :)
Where do you find all these odd bits of metal Michel. A great video again, and a perfect end result. I do enjoy your videos. Cheers Nobby
These are some pieces I have for many years. The problem is, I'm running out of.
Good video. The problem with tables with their filled in rows and columns in all its formality is that they give the appearance of being sacrosanct. Now I wonder how unique is that periodic table of the elements.......lol.
Sacrosanct...? I had to google that :)
@@Rustinox It's a good word!
Awesome job, adapt improvise overcome!!👏🏻👏🏻👏🏻
And go for it.
Well done. 🙂🙂
Thanks.
A quick second comment regarding your gear ratios, though.
Your 2mm pitch gear setting is an abcd (4 gear) setup. If your gear setup plate was calling for (for example) 72 - 100 - 80, you could ignore the middle gear entirely and your gear calculations 50 seconds in would be correct. However, assuming I'm reading the gear plate correctly (8:38 in your original video), they're calling for 40 - 80 - 72 - 36. The 80 and 72 tooth gears are locked on the same axle, so you have 2 gear ratios to worry about. The first, from input to the driven pair, is 40-80, or 1-2. Assuming 1000 rpm at the input, the driven gears run at 500 rpm. Then from the driven gear to the output you have 72-36, or 2-1. So, again assuming 1000 rpm at the input, the 500 rpm at the driven gear becomes 1000 rpm again at the output.
As a side note, it's not surprising that the ratio is an integer for a metric machine cutting metric threads. Look at the odd ratios you have when cutting imperial stuff :)
So you could replace either of the 2-1 gear pairs with another pair of the same 2-1 ratio, and you could cut your 2mm pitch. Or you could replace the whole thing with a 3 gear setup where the input and output gears are the same if you have 2 identical gears available. Say 60-72-60. That would work too and might well fit. I suggested a 30-60-72-36 setup because the sizes were close enough to be likely to fit, and because your gear plate shows a 30 gear setup being possible on gear 1 (which is often tricky, as it's the spindle gear). This latter point is moot as in your case the 1 gear appears to be the exit of the gearbox, I hadn't seen that.
Give it a try.
Not that I'm suggesting cutting an 80 tooth gear is in any way a waste of time - it appears to be useful elsewhere, it means ou can use your gear cutting plate without worrying about "oh no, I have to do this instead", and gear cutting is always good therapy.
Thanks for your input. I find it very interesting.
@@Rustinox Thanks. If you wanted to bootstrap the missing disks for your dividing head, it might also be possible. Drop me a line, I can maybe come up with a plan based on what you have.
Great video Michel, I think I enjoy gear cutting as much as single point threading. When I cut gears I use a boring bar with a hand ground HSS cutter held by set screws. and usually I work with aluminum or brass. Enjoyed, cheers!
Boring bar is a good idea. I will keep that in mind.
No such thing as primitive, if you got the job done correctly. I get the feeling you were a teacher and machining is a hobby. Keep the video’s coming.
Well no, I'm not a teacher. And it's indeed a hobby.
Hi Michel.
Hi to you too :)
Hi Rustinox, is there a possibility to contact you? I think i have some spare tools that i could send you.
rustinox@outlook.com
Primitive (satisfying)
Lol.
Excellent! Thanks for the look ,your witt and the time given.
Thanks.