Tools, Glorious Tools! #10 (Part 5) - Shop Made Gear Cutters - Tooth Fillets & Edge Cases

A very special thank you to Patrons:
Sinking Valley Woodworks (www.sinkingvalleywoodworks.com)
Glenn Trewitt
Mike Manfrin
Christopher Warnock
Guy Loughridge
Charles Frodsham & Co.
Peter John Richardson
Adam Slagle
Tim Bray
Dan Keen
Samuel Irons
Sean Kuyper
Matteo Neville
Daniel Cohen
Larry Pardi
Olof Haggren
Stassinopoulos Thomas
Florian Ragwitz
Andrew Smith
Bernd Fischer
Sam Towne
Jack Cause
Jeremiah G. Mort
Andre van Soest
Matthew Middleton
Thomas Veilleux
Dave Seff
Robin Haerens
L'Enfant Watch Company
C. A. Patrick Voigt
Mark Coburn
Bogdan Dan
Steven R. Crider
Gary Levario
Pete Askew
Jeff Armstrong
Rudolph Bescherer Jr
Robert Petz
Ralph McCoy
Jim Popwell
Kaedenn
Bradley Pirtle
Alan Carey
PaxAndromeda
John A McCormick
Thomas Eriksen
Michael Hardel
Tim Ball
Dominik Rogala
Xanadu-King
Eric Witte
Peter
Grant Michener
Jonathan Teegarden
Steve Hossner
RuKiddin06
RobinP556
Lea Bruder
Armagus
------------- Video Notes: --------------
File Downloads (Be sure to COPY/PASTE the links):
Cutter Sharpening Tool Metric: www.clickspringprojects.com/u...
Cutter Sharpening Tool Inch: www.clickspringprojects.com/u...
Clickspring Universal Gear Calculator: www.clickspringprojects.com/u...
Cutter Forming Tools Metric: www.clickspringprojects.com/u...
Cutter Forming Tools Inch: www.clickspringprojects.com/u...
Cutter Blank Metric: www.clickspringprojects.com/u...
Cutter Blank Inch: www.clickspringprojects.com/u...
Some top resources on Gear Theory:
John Stevenson's Blog Post - metalwebnews.com/howto/gear/ge...
WO Davis - “Gears For Small Mechanisms”: amzn.to/2Yj2Ben
JM Wild - "Wheel & Pinion Cutting in Horology": amzn.to/2HI6ca9
"Gears and Gear Cutting", Ivan Law: amzn.to/2FKmaUI
Tony's gear videos:
• Gears! - But Were Afra...
• 15T-M2 Let This Be A L...
Stefan on the subject of sharpening, and a discussion on profile error: • Toolgrinding: Resharpe...
Mr Pete's Gear Videos:
• SHOP TIPS #192 Intro. ...
• SHOP TIPS #199 Making ...
• SHOP TIPS #200 Making ...
• SHOP TIPS #197 Gear Cu...
• SHOP TIPS #194 Cutting...
• SHOP TIPS #193 Cutting...
Andy Pugh's Gear hobbing video's:
• Hobbing (Gear cutting)...
• A New Gear for an Old ...
"The Watchmakers' Lathe " Ward Goodrich - amzn.to/2Wijchr
Hugh Sparks - www.csparks.com/watchmaking/C...
"The Clock & Watch Makers Guide to Gear Making" Porter - amzn.to/2xuFP7I
Online Gear Generator: geargenerator.com/
Alan Pinkus’s Gear Generator - www.micro-machine-shop.com/gea...
Matthias Wandels gear generator: woodgears.ca/gear_cutting/tem...
(Amazon Affiliate links)
Cameras:
Panasonic GH5 - amzn.to/2rEzhh2
Panasonic X920 - amzn.to/2wzxxdT
Books:
"Wheel & Pinion Cutting in Horology": amzn.to/2HI6ca9
"Solidworks 2013 Bible": amzn.to/2FObS1D
WO Davis - “Gears For Small Mechanisms”: amzn.to/2Yj2Ben
"Workshop practice Series": amzn.to/2WgeGh0
Tools & Shop Products:
Optivisor Headband Magnifier: amzn.to/2HFg1FU
Norton 1-by-2-by-8-Inch Fine/Coarse India Combination Oilstone, Red: amzn.to/2tTEPb0
Hegner Scroll Saw: amzn.to/2IhteVW
Digital Caliper 6 inch/150 mm Electronic Vernier Calipers: amzn.to/2EArNRU
Generic Dial Indicator 0.001": amzn.to/2FOFTyF
Interapid Dial Test Indicator: amzn.to/2FPInwH
Saint Gobain (Norton) - 4 Arkansas Stones + case: amzn.to/2HCOAMX
Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: amzn.to/2DR5fdb
Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: amzn.to/2ITfeTa
YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: amzn.to/2G7ylv6
Hegner Scroll Saw: amzn.to/2IhteVW
Blazer GB2001 Self-Igniting Butane Micro-Torch: amzn.to/3f5Gzlh
Magnetic Base Adjustable Metal Test Indicator Holder Digital Level 14" - Tool Stand: amzn.to/2PkyoTV
Anytime Tools Angle Block Set 1°, 2°, 3°, 4°, 5°, 10°, 15°, 20°, 25°, 30° Precision +/- 20 Seconds, Machinist Tool, 10 Piece Set: amzn.to/2QFqM2Y
Consumables:
Super Pike Saw Blades Size 3/0 pkg of 144: amzn.to/2uI0QdT
Blue Matador Abrasive Paper: amzn.to/2IAFiBT
Bergeon Professional Cleaning Rodico: amzn.to/2NwcM6y

[@movax20h]

A tool, to make a tool, to make a tool, to make a tool, to make a tool, to make a tool. Great video.

[@jonathanlunger2775]

I love this channel. The workmanship, the editing, the thorough understanding of the underlying mechanisms... look forward to every upload!

[@plainnpretty]

I agree

[@satibel]

11:04 that's an engineering book cover right there

[@jfan4reva]

Videos like this are the reason I don't watch TV anymore. No commercial network would ever carry a niche series like this. Thank you Chris for making my internet screen time productive and educational!

[@Runningr0se]

I almost feel bad that I'm not going to be making any gears, because this is such a good guide series.

[@foadrightnow5725]

You are an artistic engineering genius! And your content production value is world class! Always informative, always entertaining, and always enjoyable! Thank you SO much for sharing! Cheers!

[@joshclark44]

"That's so tiny!" *a few moments later* "that's so huge!"

[@jochenheuser3142]

9th Hole, Halfway House... had to pause my round and watching Chris educate me on cutting gears 👌🏼

[@drDemonos]

На самом деле, это какая-то фантастика. Я хочу собрать все видео автора и запечатать в капсулу времени. Если что-то случится, все эти технологии помогут цивилизации вернуться на уровень как минимум начала 20 века. Осталось продумать механизм воспроизведения.

[@haugstule]

6:20 Tim and Eric: Mind blown🤯🤯🤯 BBBoooooHHHHHHHWWWWWW 🤯🤯🤯

[@bobcoombs7924]

Always amazing. The scale at which you work is mind blowing.

[@GarySmith-up1un]

Incredible skill, way over my head 🤯

[@BrassLock]

I didn't know a darn thing about gear cutters until I saw this 😮 . Matthias's gear calculator for _"Wooden Gears"_ was a beginning guide for me to see how hand-cutting plywood gears is possible. But lathe cutting of metal wheels _(by creating your _*_own bespoke_*_ gear cutters)_ seemed very complicated; however your videos helped me to understand that it's really possible. 😊

[@sky173]

Gear making has become an addiction for me. It's one of the most satisfying experiences I've ever run into in my home machine shop. Thanks for the inspiration and the quality content.

[@mpetersen6]

When I was working I cut more gears than I care to imagine. The most satisfying were Helicals. To cut a Helical your math for the index and Feed ratios have to be dead on at least a difference off .00005 or less. That's because we cut gears on machines that generate to tooth form. Gear Hobbing and Gear Shaping machinery. The nice thing there is one cutter will cut the whole range of teeth that would take a whole set of profile cutters.

[@williammorris1763]

Shop tool series are epic!🔥🫡🙌

[@Michael_Michaels]

This channel and this guy's work is so underrated! The high level of detail and explanations turn this channel content into treasure chest full of craftsmanship delights.

[@lolcec81]

Комментарий в поддержку канала и ролика, а также труда мастера

[@gseivert]

I do love how you put the blue Dykem on the gear blank being cut. Not sure why but I find it comforting.

[@samdude1953]

Do you mean Loc-Tite 609 used to glue that tiny cutter in place? That stuff come in very handy. (Dykem is great too. I use the blue, but occasionally also the green color for complicated layouts.)

[@gseivert]

@@samdude1953 No I mean the blue Dykem he puts on the outer edge of the gear blank before he cuts the gears. It’s not like he marks the tooth location and then manually cuts each tooth. It’s as if he puts the Dykem on out of habit.

[@mpetersen6]

​@@samdude1953 As l understand it Green Dykem is specifically meant for brass and other copper based alloys. When I was working I had Blue, Red and White. The White is meant for working with cast iron. For general work IMO Red is much better than the Blue. Blue Dykem flakes off far to easily no matter how clean the surface is. But the best layout fluid for ferrous metals is Copper Sulfate. Commonly called Blue Vitriol. Does not dissolve under cutting fluids or flake off. Yet polished off easily. Can be mixed at home using Copper Sulfate Root Killer. Dykem also used to have a Yellow and Purple iirc.

[@Khrrck]

​@@samdude1953I believe they're talking about the miniscule blank at 6:20 - I think it would be very hard to see the cuts without it!

[@robertbackhaus8911]

To allow him to see exactly when the cut is completed - as soon as the blue goes away, you know the cut is done. You don't want to go any further - maybe even leaving a tiny strip of blue would be best.

[@Breakfast_and_Bullets]

It absolutely blows my mind to see things like this. The idea that if you have one lathe you could use it to build almost all the parts for another lathe is wild to me.

[@Cosmic_Fyre]

Your incredible work on such a small scale never ceases to amaze!

[@Scodiddly]

Damn. A whole series of videos, and calculators so you can do it at home without too much head scratching. Massive!

[@sojiro288]

Wow I'm impressed loctite works well enough to hold it while cutting

[@billdoodson4232]

I'm quite frankly astonished by the quality of the work you manage to produce on such basic equipment.

[@dougl892]

I suggest this series has done more for encouraging clock/watchmaking than any other series I have seen. The fun side effect is that this kind of machining is not only helpful in keeping costs in-house, but a fantastic introduction to general maching too... not to mention learning attention to detail.

[@jeffkeen6943]

Amazing as always Chris!!! Many thanks for sharing your hard earned knowledge so eloquently... 🙂

[@carlhitchon1009]

Wonderful series. You've done so much work for others to get started.

[@gabrielgomescunha]

I'll never do any of this but your videos match perfectly with the mood I like for a Sunday breakfast ☕

[@SpinStar1956]

Wow! Really Nice!

[@eleanorchapple8772]

Incredible skills explanations and incredible photo video.

[@neatmachine]

Your videos are first rank! Perhaps you might consider producing a video on how you make your videos to include such things as make and model of your camera, editing software used, how you do your fantastic special effects etc.. I appreciate the effort it takes to make your videos. I would like to nominate you for a KZbin award if you haven’t received one already. Please tell me how to do? Thank you!

[@geemcd]

Yeehaa for upcoming projects!

[@pirateskeleton7828]

First tool is a tool for making the tool. Love it

[@PaulBernard365]

Outstanding series on gear cutters, thank you.

[@garywiens8625]

Can't wait for part 6: power skiving in the home shop

[@MASI_forging]

You do amazing work such a talent 👏👏

[@ruperthartop7202]

OMG. This series is great, just what i was after. Thank you

[@joevostoch8768]

Great video! I look forward to the next installment of tools, glorious tools!

[@slick4401]

Arguably the best channel on KZbin.

[@aussienebula8331]

Brilliant series Chris. The intricasy of the making and using the cutters to produce the gears from scratch was facinating. Cheers

[@dalejones4186]

Just wanted to say thank you for your time and instructions.

[@jasonweiss2773]

The best produced content on YT. Hands down, you put together such high-quality entertaining educational content, I would think you were backed by a large production budget and company. It's a travesty that your channel doesn't get 30 million views a video. I hope you continue to be motivated to make these because I sure enjoy them. Thanks for sharing your passion with us. P.S. I have never been a machinist or work with metal in any way. (Amateur woodworker) So if you can entertain someone like me with something I have no current intention of pursuing, you are definitely doing something right with your channel. You Rock.

[@johncroasdale2748]

Technically superb, spoken and practical!

[@babbagebrassworks4278]

Pin vice as collet block on grinder, going to pince that idea, brilliant.

[@jdmccorful]

Sweet!! Thanks.

[@TesserId]

The master teaches so that students eventually surpass the master. This is how the art expands into the future. I hope that others recognize how there are those that pass on their skills for this purpose. Cheers.

[@dzmitry195]

Toppingly. As always.

[@smallshoptalk589]

Thanks Chris. I know it was 17 plus minutes and you had a lot of Info to convey, but I love watching metal cutting metal. So maybe not so fast on the cutting. Love that last cut on the gear. You and ToT, love you both.

[@paulrayner4514]

Absolutely loved this series, It has taken some of the mystery out of it for me. Thank you. Looking forward to future episodes👍

[@angelramos-2005]

Amazing work,Chris.Thank you.

[@tnekkc]

fun to watch

[@uliman100]

I love your channel, always interesting and it shows how with very little you can achieve a lot... Thank you for all your efforts in making these videos. You must enjoy making videos as much as you enjoy the hobby. Videos are exceptional quality.

[@tomthumb3085]

Another really helpful and interesting video, thanks Chris. I’ve learned so much from this series.

[@tomsemo8186]

Excellent series

[@samrodian919]

Chris this was an absolutely marvellous revelation to me. Thank you so much! I have a number of broken toothed gear train wheels for my 22 year old Chinese 12x19" imperial lathe that has a milling head fitted to it. I have absolutely no idea as to the proper geometry to the gear teeth used. And no idea as to how to go about finding out the correct profile( module or whatever) for these gear wheels. Can you or any of your viewers/subscribers point me in the right direction please? I'd love to be able to produce at least a fly cutter type gear cutter to replace my broken change wheels. And before someone suggests it. I contacted the British seller ( Warco) and replacements are no longer avaliable and they were unable to tell me the details of the gear teeth profile.

[@Darren_Barclay]

Hey Chris I’ve really enjoyed this series, making gears has always seemed like a tough task for me, but you have kept it simple and laid a great foundation to get started. Thanks man and keep at it yourself.

[@ogi22]

I have to tell you he got me with his series of Antikythera mechanism. From what i remember, it took him 2 years to complete the project. This guy is just amazing.

[@rolfborsdorf8252]

i love this channel as a model builder, very well explained and you learn a lot

[@sidneyriggs9764]

Very interesting.

[@ogi22]

And subtitle of this episode should be: "When a scratch from polishing is comparable in size to your cutting tool" 🥰

[@amok42]

Thanks

[@Clickspring]

Cheers :)

[@mayhemmayo]

KEEP UP THE GOOD WORK

[@methlonstorm2027]

excellent work as always thanks

[@samdude1953]

Another great video, Chris. Your voiceovers even have an ASMR quality for easy listening. Thanks! (BTW, I'm looking forward to the next Antikythera instalment.)

[@ianhand4845]

Thank you for your excellent tutorial series. I am inspired to attempt a small gear for a repair job soon.

[@ledhunters]

Fantastic work :D

[@robvanbeusekom]

love your vids

[@Gold63Beast]

I missed your videos. Great to see a precision expert at it again! Absolutely amazing engineering.

[@Bob_Jones_]

very cool

[@benaliriadh6598]

merci pour les plans

[@markedevold1261]

👍very cool

[@magnussorensen2565]

Thanks. I will do this when I get a late.

[@kokodin5895]

if i'm not mistaken you could make cutters with more cutting edges if you make more holes for indexing in the fixture, and 4 was juat the simplest pattern to make with 2 axial measurment but i am impressed how the fixture works as resharpening tool since cuting edge profile is relived inwards the profile stays the same after sharpening even multiple times while cutter itself might get smaller but for heavy weared cutter i would also implement some kind of a stop so you resharpen all surfaces to the same depth, it would avoid the situation that one cutting edge becomes longer after sharpening and the cutter hunts with just one edge while rest remain fresh and hidden because they have nothing to do, with multitooth cutters that might be intentional to stagger the cut over multiple teeth like a broach, but with only 4 edges it would be probably best if they all cut the same

[@theashen]

I love a good flank angle

[@fir3w4lk3r]

Now you have many gear cutters could the next project be a mini Michelson's Harmonic Analyzer? Great machine, Lots of gears. :D :D :D

[@Dan-TheOracle]

#AustraliansAreMagic

[@CatNolara]

Great video again Speaking of edge cases, what is the smallest number of teeth for the "involute" cutters before the profile deviation to an actual involute is too high?

[@coyzee1]

This is viewing perfection. I appreciate the effort involved, thank you. Is there any chance of a blooper reel just to show you're mortal?

[@foadrightnow5725]

I know, right?

[@BrassLock]

Just because *Cutting Edge Engineering* failed to upload this week's dose of Aussie Bloopers . . . Right 🤔😮

[@mpetersen6]

I'm going to offer up an idea for getting lathe toolng made to make your own form cutters. Not necessarily cheap but it could produce very accurately shaped lathe tooling with the side cutting relief built in. Wire EDM.

[@nurbsfoto]

yay

[@daniel_wilkinson]

Alright, so check it out: You use tools, to make a tool, to make a tool, to make a tool, to make a gear. I'm just trying to be funny, but it is truly good craftsmanship because now you can make many gears all exactly the same.

[@eliasknapp5391]

Whats up with the antikythera mechanism? Would love seeing another episode!!

[@NProppe]

Thank you for this series, it has been awesome! Have you come across any resources that discuss how to make cutters for internally toothed ring gears on a shaper?

[@johnellison3030]

Sunday night is Aussie video night on KZbin.

[@JgHaverty]

Does relief angle matter? Like im sure theres a minimum for chip clearance and then a maximum to keep structural integrity; but is there a prescribed angle for types of cuts?

[@mpetersen6]

1.5 Module. Approximately 17 Diametral Pitch. Total toothedepth about .125". Not really that large. It is not just lnvolute or Cycodial gear cutters that can be made withthis method. Angle cutters, spline cutter (involute and parallel types), cutters for toothed belt sprokets etc.

[@c0rr4nh0rn]

Can you show the escapement cutter creation and use? It sounds like a beautiful short video (or short)

[@babbagebrassworks4278]

Alloy toothed pulleys for belt drives?

[@MattOGormanSmith]

Am I the only one imagining an Antikythera pocket watch?

[@EleanorPeterson]

A bit of a random comment, here: I've noticed that power and lighting switches in the States are 'up' for 'on'; here in the UK it's always been the opposite - down is on, up is off. What's the norm in Australia, Chris? (Making allowances for being upside-down, of course...🙃)

[@georgescott6967]

Down is on in Australia.

[@BrassLock]

​@@georgescott6967Expat Aussies living in Thailand have to re-educate their lifelong habits in that regard, but can relax on the drive home from the Bar, 'cos left is alright on the roads.

[@petegl581]

I struggle with the speed the newly made cutters are run at. Surely material cutting surface speed applies.

[@jameslake5977]

Hi, do you sell drawings of your tool systems or have you written a book about all the clock making tools in your videos. many thanks Jim (UK)

[@LunchThyme]

Chris uses a macro lens to find his real macro lens.

[@ozrc1017]

Another great video as always. Can you please tell me where you get your tool steel from in Australia? Cheers.

[@Clickspring]

hales.com.au for gauge plate, drill rod and various plate mild steel; blackwoods.com.au also good for drill rod - Cheers :)

[@jhbonarius]

Round bottom profile. Accurately describes my wife.

[@BrassLock]

I guess a _"Brassy Joke"_ will emerge from the Comments shortly.

[@user-nl6yr4lp4i]

Очень аккуратные у вас работы,спасибо вам большое.

[@suteners2111]

can you make wormgear?

[@robertbackhaus8911]

Cutting a worm gear would be done in the same way you would do single-point thread cutting. The cutter profile would be the same as for cutting a rack, except maybe with extra clearance.

[@dlightning2510]

People say they're amazed at my work...

[@larry78cj7]

What happened to the Antikythera?