Building a Gear Shaper

I've tried to make internal gears by a number of methods in the past, but it's never quick, easy or reliable with normal hand or machine tools. The gear shaper is the perfect machine to do this, so I thought I'd have a go at building one.

[@robertmason8341]

This has to be one of the best, if not the best diy machine builds I’ve seen on KZbin yet. Your use of the donor mill casting was a great idea. It retains the quill functionality to get your reciprocating motion (shaper motion) and you get the dampening properties of cast iron that all proper commercial machine tools are built from. Most diy machine tool builds I’ve seen are of the “built up” variety, with housings fabricated from steel plate and bolted together or a combination of bolted construction and weldments. The cast iron construction being more rigid and thus more ideal for machining. Can’t wait for part 2!!

[@AndysMachines]

Thanks! The only thing I'm slightly concerned about is that the rack and pinion gears on the quill are not that big and probably not designed for this type of use. That's why I used the shear pin. I'm probably being over cautious though and it will outlast all the use I'll ever need from it.

[@chrisarmstrong8198]

@@AndysMachines I agree. The rack and pinion gears will probably wear out first (after a LOT of gear cutting). Maybe a bell-crank arrangement at the top of the spindle driven from your new reciprocating arm could drive the spindle up and down directly?

[@zbnmth]

@@chrisarmstrong8198 Good point. Not sure how the bellcrank would be fitted, but I was thinking of a piston. Could you elaborate?

[@LordOfTamarac]

Amazing man, most content creators would have stretched this into a 15 part series. I love the high-level overview that shows the most interesting parts of the process in your style of filming.

[@OneManEngineering]

funny you said this. I could watch this all day. a 15 part series sounds fantastic :D. Andy always delivers!!! TIA, Greg

[@nick1bb1]

Absolutely fantastic! can't wait for part 2! I love that you are re-using/re-purposing old item to make a completely new machine- that in turn makes other parts for other machines- Brilliant!

[@anthonyalbanese1993]

That moment when you wanted to make internal gears for a while now - and have a spare milling head... Looks like another project for myself down the road. This is awesome! Thank you for sharing this!

[@garygenerous8982]

Absolutely amazing work. I love seeing you take crappy chinesium machine tools and turn them into other machine tools with amazing precision. Can’t wait for part 2!

[@Dooban]

Your channel is awesome and extremely underrated.

[@marcelosacem4940]

Simply the best. No other teacher, which he definitely is, can transmit so much information in such a precise and clear way. Learn from him and you will be a better machinist, his ideas for obtaining a very complicated process in a simple attainable way using available parts and new technology are outstanding. Congratulations 👏

[@rootvalue]

I love your videos so much. The effort, skill, and knowledge are immeasurable.

[@charlvanniekerk8009]

FINALLY !!!! I HAVE BEEN WAITING FOR SOMEOME TO TREPAN SOMETHING FOR YEARS! Incredible build and some amazing techniques. This really makes for an incredibly precise piece of equipment and endless possibilities well done!

[@gutsngorrrr]

Very impressive, taking the old mill and converting it like this, so clever. I'm looking forward to part 2

[@lumotroph]

Wow! So keen for the next one!

[@JeffPedlow]

What a great start to the weekend! Always a delight to see a new video.

[@RyJones]

You’re back! ❤

[@AndysMachines]

I never actually went anywhere, but time flies!

[@andrewdolinskiatcarpathian]

Astonishing vision, design and execution. Well done on such a brilliant build. 👏👏👍😀

[@Smallathe]

Now that is a LOT of work. WOW... a very impressive build!!!

[@FCleff]

BRAVO, Andy!

[@thecorbies]

Fabulous project, fabulous work, and fabulous explanations. Thanks for sharing this with us. Regards Mark in the UK

[@smudgemo]

Really neat stuff! One of the few channels I don't FF through at some point. Probably a combination of the overall length and not wasting a lot of time showing completely obvious disassembly in fast-motion. The subject matter is most important, of course, and I find this inspirational as I'm mostly an amateur hack machinist.

[@stefanguiton]

Excellent video!

[@2OO_OK]

Very Impressive! This 14 minute video must have taken 40 hours of real time to make.

[@DudleyToolwright]

Very interesting project. Thoroughly enjoyed.

[@wildgophers91]

hahaha, you got me with "The two, in no way fit together"

[@joell439]

Always exciting, interesting, educational and entertaining content that I eagerly look forward to watching. Thank you 👍👍😎👍👍.

[@hpevans9041]

Fantastic work Andy, you certainly have a wide range of skills

[@irritantno9]

This channel covers so many different topics I'm interested in, and I really have a limited interest in gears. Just became a patreon supporter.

[@wes7715]

Best part is when he said "gimmie dat, gimmie dat" while building his monster. KEEP SPEED! Ok ok oh god I could say so much. But the transition from CNC spot drill to HAND DRILL really got me. 😅Pure genius.

[@brucewilliams6292]

Very impressive! You do such well thought out projects.

[@pawekowalski7469]

I am so impressed with your designs !! 👌👍👍It is a pity that I do not have such knowledge in the field of CNC. 🤥Greetings from Poland Jestem pod wrażeniem twoich projektów !! Szkoda, że nie mam takiej wiedzy z zakresu CNC.

[@CRILIKk]

Wow , best explanations on gears ever , thank you 🙏

[@LitchKB]

Spent most of a day researching how I was going to do this for the ring gear of a planetary setup last week... Then presto! Andy beat me to it. Kudos.

[@georgedreisch2662]

Simply brilliant! Looking forward to the math involved to get it all to sync. Also hoping on more elaboration on inside gears, particularly, tooth profiles.

[@MyLilMule]

Absolutely brilliant. I love it.

[@homemadetools]

Good work. We shared this video on our homemade tools forum this week 😎

[@RustyInventions-wz6ir]

Interesting. Very nice work

[@IrenESorius]

Impressive! Cheers and thanks for sharing Andy,, 🍻😎👍‍‍👍‍‍

[@howtorepairpendulumclocks]

totally brilliant. Inspiring!

[@eyuptony]

Brilliant, enjoyed watching. Tony

[@Thermo88]

impressive work thank you for sharing your experience

[@ianreynolds9693]

Absolutely amazing!!

[@barryvj171]

Legend !! Who would have ever thought about doing that !!

[@TheDistur]

That is so cool. Once you have enough tools you can make so many other tools!

[@samrodian919]

You sir are a mechanical genius. I loved watching that!

[@ledfootlou2540]

I’m loving all the gear making videos, keep up the good work!

[@f.hababorbitz]

WOW! Your video production is always so well done. Your engineering and clever design ability (i.e. talent) is exemplary. This is not applicable to your implementation, but I turned a motor shaft down a few years back, on a new 3 phase motor I was fitting on my lathe. In my case a V-belt pulley. I didn't think about it at the time, but I left a sharp corner on the reduced shaft. Within 20 hours of running, the vibrations of the motor caused a crack to develop at that corner and the shaft with the pulley went rolling down the shop floor. Big lesson learned. Never thought that small vibration and radial load would do this on a 19mm shaft, at least not in my lifetime.

[@rodneykiemele4721]

Your videos are very impressive, Thank You very much for sharing them.

[@rickpalechuk4411]

Cool build Andy, looking forward to the rest of the series. Cheers

[@kevinsellsit5584]

Spectacular! That has money maker written all over it! ;)

[@fenchelteefee]

Just pure awesomeness

[@alliwantedisapepsi1492]

Part two? really. I hate suspense. Anyway, this just looks like another awesome build. Top notch build for a difficult challenge. Great jOB.

[@kisoia]

Excellent work and video, thanks!

[@TheDumry]

So much garbage on youtube that gets millions of views. Content like this is why I watch youtube, I'm rooting for you that your channel will blow up big, you deserve it.

[@alitn588]

Brilliant idea 👍👍

[@aaronsilas7024]

Love the fact you are sinking your teeth back into the whole gear topic. I believe its somewhat of a black art for most machinists s its great to learn about it.

[@thomasstover6272]

Thanks, Andy! A new machine to obsess over! I happen to have an old XLO mill head….hmmm.

[@Be-positive-on-life]

Help me a lot. Thanx brother

[@seimela]

The information I wasn't aware of is the blank also rotates with cutter

[@justRD1]

Awesome!!! It’s like my maker Channels know I’ve been tooling up to make gears!

[@stevensmart8868]

Nice work. Thanks for sharing

[@user-gh3dd5or3q]

Технари друг друга всегда поймут. Шикарная работа!

[@marianodiaz461]

Great video! The only thing that I would change is to make the worm taper , but your system works good as well…keep up the good work!

[@improviseddiy]

Nicely done! Thinking outside to box here. 🤔

[@gerhardgroenewald6560]

o yes!Dont forget the relief on up strokes!Somebody with your calibre can easily program that in.Cant wait to see Andy...

[@older-wiser-better]

Very cool upcycling

[@HM-Projects]

This is excellent, cheers.

[@Dellpodder]

Your videos are amazing; thanks for making them! Cheers from across the pond.

[@machineworld1873]

impressive it is my first time to see that 😍

[@rabahchikh8918]

Good job c'est une idée géniale

[@jimsvideos7201]

Brilliant.

[@LordPhobos6502]

6:30 'They call me Dr Worm... I'm not a real doctor, but I am a real worm'

[@josecarlospoggian149]

Thanks a lot!! 👏👏👏👏👏👏👏👏👏👏👏

[@stupid-handle]

Well done Andy! From your last video I inferred the finish would be due to the rotary head not being in perfect sync with the spindle, as in something you could solve somewhat easily, but great build otherwise! I don't personally like much the fact that quill's rack and pinion are taking all that intermittent load, but (as originally intended) the mechanism seems able of handling moderate loads, so as long as you don't give it too much depth of cut I guess you should be fine. And if that fails at anytime you've got more than enough skills to find a suitable solution. All the best!

[@bulletproofpepper2]

Thanks for sharing.

[@glennwright9747]

Awesome build. When I do projects they keep getting interrupted by 100 other tasks and months later my project may get completed😊

[@ollied1981]

Brilliant stuff :)

[@ImpactWench]

Can't wait!

[@juliocesardemoraesbarros5585]

I have made a planetary gear set 8mm. Tick using a a laser cnc cutter and it's working perfecly

[@Smartzenegger]

Very nice. See you in Part2D2. :)

[@matter9]

Phenomenal.

[@deanharris7149]

Awesome.

[@mrechbreger]

I'd be interested in power skiving, I'm doing quite some gear hobbing myself.

[@andli461]

Amazing! But have to wait for part 2… 😬😉

[@adityabhanuwanshe4381]

Amazing transformation and very good machining 👍 Just a little upgrade tip add another stepper motor to bed horizontal movement you will get rack shaping machine too 🤑🤑

[@meocats]

Good idea

[@JLmcct]

You are mad but genious !

[@micro04thai27]

cool amazing skill

[@federicoae7671]

Great video, as usual. Are you still working on the T-800? I would really like to see that finished.

[@AndysMachines]

Thanks! Yes I am. In fact I need this machine to make some of the T-800's gears.

[@chimpera1]

I love this

[@KW-ei3pi]

Thank you! You are such a great resource for all things "gears" ! Home shop engineering is so enjoyable. Thanks for all of your great videos! PS: Consider creating an email address and adding it to the "About" section of your KZbin channel for direct communication. Regards.

[@joansparky4439]

inspiring to say the least 👍

[@user-mg9mg1dy8n]

Nice work 👏 💞💞🌺😘

[@glennmoreland6457]

You might want to redesign the upper crank for the linear motion with a slot so you can adjust the stroke... 😐🇬🇧

[@tradingisthinking]

gear skiving is more interesting , keep going on that bro

[@AndysMachines]

It is! The problem is it needs a specific cutter for each number of teeth, and the geometry is much more complicated. A shaping cutter (which looks very similar) will cut any number of teeth, like a hob.

[@JesseSchoch]

great job andy!!! I'd love to know how much force it takes to cut a chip with that setup. I did a small experiment on a 9x30 lathe and it didn't seem rigid enough. Also, why not just drive the cut with your Z motor? Would it stall or were you just worried about ware?

[@AndysMachines]

Thanks! It's actually capable of applying a downward force on the cutter of around 6000N (~600Kg) in the middle of the stroke. This would possibly be enough to strip the quill gears but hopefully the shear pin would go first. I don't know how much force it actually takes to make a cut, but considerably less, even when cutting steel the motor doesn't appear to be under much load at all. Using the Z motor (Nema 34 stepper) would be much slower, have less force, and also there would be more backlash as when using the quill I lock the head to the column.

[@slypig24]

I liked the oscillating link. Could make the crank arm length with a slot, to allow for different offset, and different length of stroke.?

[@AndysMachines]

Yes, I did think about doing something like that and other people have mentioned this too. But for now at least it's unlikely I'll need to change the stroke for the gears I want to make.

[@dalelathwell7219]

Well, that sure looks a very handy tool was you a machinist by trade ? I've made clock gears in the past and found them very challenging with manual dividing heads would love a stepper motor dividing head like yours 👍

[@pierredessage5530]

Merci infiniment!!!

[@azenginerd9498]

Another fascinating build! No need for adjustment on the stroke length? Or does that add a level of complexity not warranted in this design?

[@AndysMachines]

I chose a stroke length to suit the type of gears I want to make, I probably won't need to change it, if I do the only way is to shorten or lengthen one of the lever arms.

[@heronguarezi6501]

A constant oil supply will be a must

[@lawmate]

Amazing work! Do you need to add extra lubrication for the quill and rack and pinion now they are constantly in motion? Looking forward to the next video. You'll be making a lot of gear trains when this is done!

[@AndysMachines]

Yes, I did make sure it was all well lubricated when I reassembled it. The quill is easy to lubricate in use, but the rack and pinion gears are not so easy to get to without pulling out the gear shaft.

[@lawmate]

@@AndysMachines ah yeah. Maybe a little oil dripper above the pinion?

[@gregwmanning]

Bold project Andy. Did you meticulously plan and design everything before you started or figure it out as you progressed?

[@AndysMachines]

I usually make a broad plan to start, but it often evolves as I build it. Usually it's steered by the parts and materials I have available. You'll see in part 2 how the control system evolved.