- Joined
- Oct 31, 2015
- Messages
- 469
Well I finally quit hem-hawing around and did something with this gear .
First, I cut off most of the hub on the bandsaw and milled it flat, leaving a 0.100" boss.
Then, I drilled 1/8" holes in the corners of the hex. I milled the flats using a 1/4" end mill.
After finishing the corners with a triangle file, I think it came out pretty good.
Then, I chucked the old gear in the lathe and turned down the gear teeth. I removed the rest of it with a parting tool.
Then, I bored out a recess to accept the boss on the gear.
That's as far as I made it today. Next will be to mate the two halves and get the bolt holes drilled. I was reluctant to try making the hex bore in the gear at first, because I doubted my ability. Then I got to thinking that I could try it, and if I screwed it up, I could always bore it out round and go with my original plan. It turns out that it wasn't that big a deal. This is a better situation since the bolts won't be taking a shear load now.
And oh by the way, you wouldn't recognize it, but the rotary table in the pics is the one that came with the mill. It's a little rough around the edges just like everything else, but it worked well. This was the first time I've used it.
First, I cut off most of the hub on the bandsaw and milled it flat, leaving a 0.100" boss.
Then, I drilled 1/8" holes in the corners of the hex. I milled the flats using a 1/4" end mill.
After finishing the corners with a triangle file, I think it came out pretty good.
Then, I chucked the old gear in the lathe and turned down the gear teeth. I removed the rest of it with a parting tool.
Then, I bored out a recess to accept the boss on the gear.
That's as far as I made it today. Next will be to mate the two halves and get the bolt holes drilled. I was reluctant to try making the hex bore in the gear at first, because I doubted my ability. Then I got to thinking that I could try it, and if I screwed it up, I could always bore it out round and go with my original plan. It turns out that it wasn't that big a deal. This is a better situation since the bolts won't be taking a shear load now.
And oh by the way, you wouldn't recognize it, but the rotary table in the pics is the one that came with the mill. It's a little rough around the edges just like everything else, but it worked well. This was the first time I've used it.