Emco Super 11 Change gears, gearcutting and threading

[@ThisOldTony]

nice work but they leave some pitches out of the gearboxes so every now and again you can skip the job and relax. you're not supposed to make your own change gears. those charts are made up. you got really lucky.

[@IBWatchinUrVids]

Aren't you supposed to be making the next video I'm waiting so impatiently for? :)

[@OstapHelDesigns]

@@IBWatchinUrVids This Old Tony couldn't find right gear for his camera, so he is relaxing now lol 😂

[@andypughtube]

The tables are made-up, and are incomplete. It is worth taking the time to make a spreadsheet to see what pitches you can actually make. There are more ways than one to make many pitches. This can often save the trouble of changing pick-off gears, or allow you to make a pitch that you don't have the book-gears to make. My Chinese lathe seemed to have an interestingly designed quick-change box where every single change in pitch seemed to require a swap of pick-off gears as well as changing the quick-change.

[@Vladviking]

That would be my answer, if it's not in the gearbox it doesn't need to be done. Not being a geniuos tho I was wondering if a imperial setting might of covered the missing metric setting on an accident

[@abfal2003]

Yeah give it to him.

[@surmetall5596]

I have received a mini heart attack at 5:26 I haven’t seen the small piece of paper and thought: "OH GOD NO! he`s drawing in the Tabellenbuch!!!" Perfect addition to the Sunday afternoon coffee! Your videos should be shown in vocational school! Unfortunately with this beautiful gear set, my last hopes are gone that you change your mind and mount an ELS III to your EMCO. Great video!

[@arnljotseem8794]

Me too. So unlike Stefan to draw in the book :-) :-)

[@extradimension7356]

Anybody know what / which book Stefan is using ? Looks really good !

[@zephyrold2478]

I second that.

[@arnljotseem8794]

EXTRA DIMENSION IT is a German book also available in English from Europa Lehrmittel. Very good and lots of condensed info: www.bookdepository.com/Mechanical-Metal-Trades-Handbook-Ulrich-Fischer/9783808519141

[@extradimension7356]

@@arnljotseem8794 Ohhh That's fantastic , thanks so much, my German and technical German is not too awful, but slow. So the fact that there's an English version will really help speed thing up ! Thanks so much @Arnljot Seem

[@robertklein2816]

A little Bakelite with my coffee this morning. Chevrolet used it for silent timing gear in their "Blue Flame" six for decades, and yes there may be just a smidgen of asbestos for added flavor. Got to love it when Stefan makes 40 parts for a 1/4 in of thread in under 35 minutes.

[@joandar1]

Robert Klein, same thing in Australia under the Holden badge ( A Chevrolet Company with an Aussie Coach building company name) their early Six's used these gears on the camshaft with pretty good reliability and quiet operation for many years. Cheers from John, Australia.

[@googleuser859]

Great video Stefan, thank you. Also, as someone born with a genetic lung condition and having a 27% lung capacity at 30 years old I agree, looking out for your lungs is very important. Minimising exposure to dust is essential, you don't want to be in my position, trust me.

[@DanielPerez-bn9bi]

Even if though I am not a machinist I really appreciate your videos, and your attention to detail. There is something to learn from your approach to problem solving. Thanks for sharing!

[@bostedtap8399]

Phenolic, is an excellent material, both Linen and Paper impregnated version, "Tufnol" is the most known brand name here in the UK, "Carp" and "Whale" are their product name, but an absolute mess to machine, as you can see. We use if as a non marking clamp on chromed rod. Always a pleasure, and education to watch Stefan. Thanks for sharing and best regards from the UK.

[@outsidescrewball]

Stefan....your video production quality, discussion, demonstration, build....IS EXCELLENT.....lots of lessons within the video...thank you for your craftsmanship and sharing your TIME

[@brianu2871]

With the care you take, the gears you made will last a long time. Phenolic gears are use in many commercial gear boxes. Great job !

[@SteveSummers]

Thanks Stefan, very interesting. I believe I've seen phenolic gears before in devices. 👍. Beautiful work as always.

[@fasousa4798]

My myford S7 has a phenolic tumble gear

[@tomclark6271]

Yes, in West Germany 1971, I discovered that my 1960 Opel Kapitan (GM company) straight 6 had helical phenolic timing gears when they failed. They simply disintegrated, and according to the parts guy, it was a common problem.

[@deonels8934]

@Stefan, you're a real role model. As an unqualified CNC machinist in South Africa, very few people here can help me with the finer detail of the trade. You answer all my wildest questions and give me so much advice and tips. Thank you for that.

[@peterwiley3829]

Had to smile when I saw this because recently I had to make a bunch of 14.5 x 0.75 male & female threaded parts for Primus burners. Fortunately my Emso Maximat 11 came with the accessory gear set for the non-standard pitches so I didn't have to make the gears first. But - I've certainly had to in the past, with other lathes, for oddball pitches. Anyway, nice job. Those Emco lathes are beautifully built, I don't ever plan on parting with mine. One day I'll fit a DRO though.

[@mpetersen6]

Stefan, I cut a lot of gears and splines over the years in my old job I retired from (automotive engine and drivetrain) for replacement parts in components. These were cut primarily with gear bobbing and shaper equipment. A lot of the gears were Fellows Stub Tooth in which they used the the pitch diameter of one size and tooth height of the next smaller pitch. This would be expressed as 10/12, 8/10, 12/14 etc. What I'm getting at is is there a Module Stub Toothed for

[@jrkorman]

@32:43 Stefan "I might need a little relief on that tool!" Do remember the dust when cutting old phenolic circuit board years back. Lovely smell too!

[@mtraven23]

glad someone else caught that tool shape shift a bit

[@bobengelhardt856]

33:20 "That's a nice .75mm thread". It is - it's perfect and I'm glad to hear you say so. Not "That's pretty good" or "That's OK" or some such. Not only the thread, but the video - thank you.

[@blenz88498]

you can prevent "tear out" on micarta by backing it up with pretty much anything. Most of the time I have used another piece of micarta, but alum at least .040 works quite well.

[@techno_mesh]

Hi Stefan, very nice video, especially if you only have to look at the first 3 teeth and the last one. I have an Emco Maximat V10 lathe with the vertical milling column. It was my fathers machine that I inherited when I was 18. I am 55 now and my shop is too small so it is stored in a wooden box and I bought a "bernard" Chinese lathe that is much smaller and without a gearbox (you only do it by swapping gears which is a pain in the neck). Your video recalls the times when I made m=1 gears and the stress of doing all the repetitive work fearing not to end up with a tooth overlap. At the end of those tasks I always wanted to automate the rotary table brake and rotation at least. I am following your channel for a couple of years (excellent content) and guessed your height might be close to 170. I had to get myself into the mood to see NY CNS's video about your shop (due to its length) and was surprised that you are 203. At the end it was a very enjoyable video. I would not like to get with you on an argument about who is the next one to use a machine at your job.

[@andrewprestridge4000]

Great job on your project and description. The use of such a transmission affords many different resultant ratios - and thread pitches.

[@willemvantsant5105]

Brought back memories making a 127 Z phenolic change gear some 30 years ago for my Australian Hercus Lathe using compound indexing head. Excellent info regarding the layer construction of Phenolic round verses sheet strength.

[@johnnyholland8765]

Found your channel and subscribed through This Old Tony and so far am very impressed. I use that same material and also something called Garolite (may be a trade name) that I purchase through MSC here in the states. Use it for a lot of different things. It is also heat resistant and an excellent insulator. I build fixtures for induction braze machines so these qualities are much needed. It is rough on cutters. The material is so dense that heat stays at the surface being cut which will break down a cutting edge quickly. I use only carbide and your use of the shop vac is also correct. It is nasty stuff and the dust gets everywhere. Great job.......

[@klauswittrupjensen]

@32:42 Stefan realized how convenient it is to have a D-bit grinder in the workshop. Saved his bacon :-D

[@yt66228]

Great job. I have the same lathe which I purchased more than 30 years ago. Great lathe!

[@harrywilson3396]

Harry from Texas USA you are a Wizard Machinist I enjoy your many jobs fantastic work 👌

[@harrywilson3396]

Thanks for the reply Stefan you must have served a very educational and skillful apprenticeship worked under some very smart journeymen or you are self taught you have an amazing mechanical skills

[@AmateurRedneckWorkshop]

It was great watching you work. Thanks for the video.

[@dalejones4186]

Love watching your videos Stefan. Very informative and your a very good demonstrator. Learning from someone with your knowledge is awesome. Thanks again.

[@stemer1149]

Very nice. I have an EMCO 5, which has change gears only and only the metric gear set. For imperial, it uses some approximation for the 127/50, there was an imperial gear set from EMCO which I didn't have. I 3D printed the gears per EMCO table in PLA, these gears have been working fine for 2 years now. It's a much smaller lathe though.

[@BossWelder81]

Very fun to watch you work. I learn a lot just seeing how you approach things. Middle Illinois.

[@iTeerRex]

And that's how its done boys and girls. Thanks Stefan for the lesson, and a pleasant video. btw Is phenolic better in this application then say aluminum.

[@EmmaRitson]

Id say it's quieter running

[@jrb_sland5066]

Not only are the phenolic gears quieter, but they will reliably fail at over-torques which will break the phenolic teeth without any injury to mating steel gears. This safety feature was commonly found in movie projectors where there was a likelihood of an occasional film jam that would seize a sprocket shaft.

[@iTeerRex]

@@jrb_sland5066 Ah ha.. The reason for my Q was to make it tougher, but its fragility is actually beneficial. Then its a good idea to always have at least one phenolic gear in the set up.

[@jrb_sland5066]

Yes, precisely. I have seen machinery that includes shear pins on shaft couplings that serve the same purpose, and of course we use fuses and/or circuit breakers in electrical systems to prevent fires caused by too much current melting the wires. Etc, etc...

[@zachaliles]

@@jrb_sland5066 it's also fairly common to use a lesser grade bolt in certain areas such as a grade 5 or a grade 3 bolt to act as a weak point or engineered failure point.

The 95 tooth gear is there only to transmit the rotation and bridge the gap, it has no effect in the reduction ratio. Any gear that fitted in the available space would do and probably saved you some work. Not as fun or fast, but you can also order very cheap 10mm thick mod 1 gears in steel from the popular auction site (the 40 teeth is going for less than 5€ with postage). I've done it before because my (used) lathe was missing the change gears, only had to bore them and add the key.

[@SamEEE12]

Thanks for sharing Stefan, I always learn something new when I watch these videos.

[@billrichardson4873]

Great video Stefan, I always enjoy watching your skill and expertise....

[@TomChame]

Absolute perfection from start to finish, thank you for sharing.

[@georghofmann1782]

endlich wieder Späne und gepflegte Maschinen-Unterhaltung 😁

[@ArtOfGottiKa]

Genau. Bin direkt süchtig nach diesen Dingern....

[@garys9694]

@@ArtOfGottiKa u r both ass holes, speak english, Stephan does, he is directing this video to english speaking people

[@menow.]

"I'm very pleased" means it's better than most of us could hope to do.

[@toddk.5873]

Nice job Stefan. Thanks for taking the time to show that. Good video.

[@euclidallglorytotheloglady5500]

Fantastic as always! Interesting material..

[@CapeCodCNC]

Those gears will last forever. The Emco 7,8, and 10 used phenolic gears in the head. They only went bad when you tried to shift speeds before stopping. You could retire making gears for those as they are now made from unobtainium and many ham fisted gear grinders had those smaller lathes. Great video, thanks!

[@JamesDedmon]

Years ago I did phonic gears. There were quite common in old textile machines, here in the states. I machining a lot of Delrin or UHMW for projects, out of sheet using a similar method.

[@GreenridgeMetalWorks]

Very nice! I've noticed that even with dust collection after a long job working on phenolic I'll have sinus problems for a day or two.

[@TEFox]

Ah, the classic few seconds of blank footage where an unseen large hammer comes out to remove stuck change gears.

[@StefanGotteswinter]

*pssssst*

[@doubledarefan]

25:30 What's with the blackout❓ 27:30 Why not use a strip of paper between the gears to help with the spacing❓ 29:05 Saw that coming!

[@ianide2480]

Took my brain at least 2 minutes to catch up when he said "I don't have a thread pitch gauge so I'm using a nut" then he produces a thread pitch gauge like 10 seconds later. The first statement, I believe you meant a Go, No-go gauge (or something similar). If not, well I'm still confused.. hehe Love yur content Stefan, keep up the great work.

[@rallymax2]

Hey Stephan, I feel your change gear pain. My Hardinge has a 33.3 DP with a 20deg contact angle if you can believe it. Which means there’s absolutely no involute gear cutters in existence to make the 127T I am missing to be able to do metric with an inch gearbox. So I’m stuck with single point hand grind or getting fancy with the material choice on my 3d printer.

[@Preso58]

Excellent work again Stefan. I am wondering what formula you use for setting the tooth depth? Regards , Mark Presling

[@tedchambers4381]

love the little adjustment to the threading tool . :)

[@imysteryman]

Your a true Craftsman, your very good at what you do. It is sure a pleasure to watch your video's, I sit here watching like ET and sucking it all in.

[@lukasdon0007]

You need that electronic leadscrew kit from Clough42!

[@takisbakalis]

i am building it for sure

[@surmetall5596]

or an ELS III from Rocketronics. Thats an excellent device with really handy features.

[@takisbakalis]

@@surmetall5596 While it's a nice product, they luck a bit in presentation, nor engilsh instruction (couldn't find by browsing their site)

[@sansdecorum4600]

@@takisbakalis Absolutely! Of the several commercial products, and those successfully created in the home shop using Arduino tech, James of Clough42 fame strikes me as having the most professionally engineered product. (I suspect his day job is in some engineering discipline.) I would like to have seen a multi-line LCD display or perhaps a touch screen offering, but I suppose that could be accomodated easy enough if someone was ambitious. Now, I just need something better than a 20 year old 3 in 1 machine to put one on.

[@takisbakalis]

@@sansdecorum4600 touch screen not that good to be on the side of a manual lathe, but yes, the interface can be much better, but it's at its beginnings

[@murdokgsanchez]

Hola 😊 gracias por tu contenido de videos educativos e ilustrativos, me puedes hacer el favor y indicarme como se llama tu libro donde sacaste las fórmulas para el piñón y de antemano gracias y saludos desde Colombia

[@reox42]

Just thread 1.75mm right handed, then 1mm in reverse left handed. I swear it works!

[@mpetersen6]

I always hated cutting Micarta (trade name for phenolic). We used it for pump bushings and insulators for bearings in seam welders and on broken tool detector

[@bobolander]

great video sir. FYI/SA, EMCO still has change gear sets for the Super 11, or they did two years ago when i realized that it was cheaper for me at the time to get the gears rather than buy the tooling needed to cut gears...they weren't cheap but worth it. had I the dividing head and the gear cutters i'd have done it myself. any chance we mere mortal Super 11 owners can get the cut plan for the top slide guard you had laser cut???

[@pgs8597]

G’day Stefan, nicely done as always. Cheers, Peter

[@hughcoleman3866]

I was watching you putting that 95 Toothed gear on and wondering how long it was going to take you to realize you needed a smaller spacer gear behind it... The anticipation near killed me!

[@Vladviking]

Great stuff IMHO I serviced and ran 16 Kinoton projectors that all used various sizes of phenolic gears as large as several inches in Dia.. I would sure use it like you did. Seemed to me they "wore" much better than metal would have.

[@douro20]

It's best to use carbide or CCBN/PCD when milling or drilling in Micarta due to it being highly abrasive. Biax! Did you buy that new?

[@sampitts7044]

Great video 👍 I got the manual you were talking about in previous videos it was written in German 😂 but I still use it at times. I always like the way you make things come to life 🙂:-)

[@roylucas1027]

Great video. You make it look so easy. Thank you.

[@billrichardson4873]

You're the man Stefan!!!

[@HotAxleBox]

Thanks for sharing. I'd be interested to see how Vesconite holds up

[@arnljotseem8794]

Most entertaining and educational. Funny how the threading tool suddenly got a notch on the left side between two threading passes at 32:34

[@rlsimpso]

Great information regarding the phenolic material. I think I would have started with the round type and found out the hard way. As mediocre as my Chinese lathe is, it came with change gears for the two pitches I cut most. Those are .75mm and 11-1/2 TPI.

[@bugrobotics]

Enjoyed it Stefan! Thanks for sharing.

[@megabytephreak]

Why did you need the 95t gear here? It doesn't seem to actually be participating in the ratio, so couldn't you have just used the 120t or 127t gears instead? Just trying to complete your set of gears for the Emco?

[@csacsamolnar]

Well, it is a really good question, you seem to be right.

[@EDesigns_FL]

You are correct. A single gear on a shaft just reverses rotation. Changes in reduction require two gears on a shaft. I'm surprised that Stefan did not recognize the situation.

[@scottr939]

Huh? He shows what the book says he needs in the beginning, and he shows all 3 new gears being installed and used towards the end.

[@EDesigns_FL]

@@scottr939 Think about the what's going on. There is no change in reduction with just one gear on a shaft. It's only changing the direction of rotation between gear sets. Though his manual specified a specific gear, it was based upon providing sufficient clearance and using a spare gear not otherwise required from the stock gear set. He obviously does not have all the gears that originally came with the lathe. The manual for my lathe does the same thing, but if you understand what's occurring you can save time and just use the most convenient gear. When I saw Stefan using a large gear as a spacer, it became abundantly clear that he hasn't set change gears very often. I either use a spacer or the smallest unused gear.

[@megabytephreak]

I should say though, excellent work, even if it was more than necessary.

[@zvonibab]

Well done Stefan! Knowledge is law. Cheers

[@KravchenkoAudioPerth]

Nice video Stefan. I like the grind for clearance on your threading cutter. I had to do a double check. wasn't that a perfect point a few seconds ago? Yep!

[@paulwomack5866]

It might be a second cutter, kept for the purpose... :-)

[@denniswilliams8747]

The chinese mini lathe use much the same change gear set up. Thanks. As always fine work.

[@RaptorMachineToolCo]

Very nice Stefan! Thank you! I will apply this to my super 11 lathe .

[@2lefThumbs]

Couldn't you double/halve the intermediate gear on the 1.5mm setting (ie just make one additional geaf)? Maybe that stack wouldn't fit on the banjo?

[@StefanGotteswinter]

that would be a 127*2 gear. quite large ;)

[@2lefThumbs]

@@StefanGotteswinter ouch, fair enough👍is that 127 tooth gear part of the inch set ( being half of 254)? Having seen the rest of the video, I sas surprised there wasn't an idler/middle axle already on the banjo, all my cheap chinese lathes have had one- nowhere near the quality of the one you made of course👍👍

[@mpetersen6]

@@StefanGotteswinter Stefan, there is an online gear train calculator. Google scientific 601. Just enter the ratio, minimum and maximum number of teeth and the amount of steps.

[@63256325N]

Well done! Thanks for the video. 👍

[@andreadifebo157]

Hi Stefan, I own the same lathe, and I have not clear what are the correct operation to stay in syncro while threading: seams like you never disengage the feed, is that correct? you engage the feed, make a pass, stop the motor, backup, invert the feed, turn on the motor to travel back , stop the motor, advance, invert the feed etc... I guess wrong

[@manfredbobski8114]

24:50 "very entertaining situation" had me rolling

[@OmnieStar]

Have you ever drilled through a 1.2.3 block? Or a vice or chuck or anything? On accident of course.

[@OstapHelDesigns]

Well done as always! I'm hunting for an Emco Drehmaschine on Ebay Kleinenzeigen for a while, hope I can get model 10 in a good shape :)

[@bterzini1]

I'm surprised you didn't use your Electronic Positioner on your rotary table.

[@bpark10001]

This is odd! I have the imperial version of this lathe, and I can cut metric 0.75 with the gears provided (8 to the inch leadscrew, use 120/127 gear pack in headstock side). I can also cut 1, 2, 1.5, 0.6, and 0.5. On my lathe, gearbox ratios (on the 1-2-3-4-5 lever) are 24/16, 24/14, 24/12, 24/10, 24/9 (to give 16,14,12,10,9 threads/inch) with A-B-C lever in C position. B and A position halve the ratio, giving imperial threads double and quadruple those in the above list. All of this is with 30T gear on spindle and 90T gear on the gearbox.

[@raymondhorvatin1050]

nice gears and great machining

[@stanervin6108]

You have it covered, Stephan. No further comment. 👍

[@dennyskerb4992]

You gotta be doing an egress part ! I’ll wait for your announcement.🕰

[@sledgeoc]

From what i have seen, only makers from the us take part in that. I guess they want to stay true to the original Apollo program, where no german engineers were involved what so ever

[@matsekelund4368]

@@sledgeoc Wernher von Braun!!!

[@Poppi2006]

Dr. Konrad Dannenberg

[@bluebalute]

@@matsekelund4368 I think he was being quite sarcastic. "what so ever"

[@matsekelund4368]

@@bluebalute You're probably right. I didn't catch it the first time I read it. Thanks.

[@sblack48]

How much running clearance did you leave between the axle and sleeve for grease? Your parts always look so perfect.

[@Rustinox]

I think your dust extractor works very good. But just to be sure, can't you come over here and test it in my living room?

[@opendstudio7141]

Clough 42 is developing a electronic digital gearbox for his lathe. The development is near completion and has generated quiet a bit of interest among his KZbin viewers. It's very interesting and worth checking out.

[@colinsalter3516]

Great job . Interesting video.

[@fredgenius]

Very nice! Wish I could afford to upgrade from my Chinese mini lathe, but I might think about fitting some extra gears...

[@alexmclennan3011]

You make it look easy!

[@EmmaRitson]

Why didn't you use your shaper for the keyways?? :D

[@StefanGotteswinter]

feeling better? 🤣

[@mpetersen6]

Or a set of keyway broaches. Ducks behind solid wall. 🤑🤑

[@tsclly2377]

always amazing with a tad of humor

[@akisdrosos]

Excellent work!

[@niltonpolydoro1]

A very nice and interesting vídeo. Congratulations from Brazil. Eng. Nilton Polydoro

[@tyhuffman5447]

Thank you Stefan.

[@jpgarcia90]

32:41 to 32:43... ninja grind on your thread cutting tool :D

[@romo4301]

Klasse Video, sehr gut erklärt und wirklich schöne Zahnräder! Wo gibt es so Material (Schichtpressstoff) zu Kaufen? Gruß Robin

[@StefanGotteswinter]

Dabke! Ich kauf entweder Reste auf Ebay oder bestell bei Sahlberg.

[@romo4301]

@@StefanGotteswinter Alles klar 😃👍 Danke!

[@warrenjones744]

As we might say to @joyofprecision, you went "Full Watchmaker" on the extra change gear bolt! Beautiful work Stefan. And... I might add... Nice & quiet!

[@hadinossanosam4459]

I always wonder how the number of teeth of "intermediate gears" (like the 95-tooth gear here) is chosen, because it doesn't really affect the gear ratio, and yet someone didn't specify a 100-tooth gear, or "any gear that fits", but a 95-tooth gear specifically... or maybe put differently: why didn't you just reuse e.g. the 120-tooth gear instead of making the 95-toothed one?

[@Smallathe]

Very nice... thank you for sharing!

[@rondean2918]

"WARP 9 Mr. Stef!!!"

[@bookerol]

Some people have way too much fun!

[@waldemarii]

Hello. Nice video again! What is the MT4 to MT3 reduction sleeve witch you are using on the MB4?

[@deemstyle]

That boring head looks quite nice! Can you comment on the brand?

[@ryebis]

Interesting, do you see any value in ditching change gears for an ELS ?

[@StefanGotteswinter]

A ELS is a great thing - But the gearbox on the emco works nice enough, to not tear it apart ;)

[@swanvalleymachineshop]

Nice job , i see you had to relieve the tool mid way . Cheers .

[@HM-Projects]

Watching this again I just realised you re-ground the endmill between 2nd and 3rd pass of threading. Curious, was there a reason ?

[@Liocharis]

Hello I am going to purchase similar lathe. What is the rpm setting for threading? What is the rpm setting for the chuck? Thank