Shaper Machine - Involute Gear Cutting

[@1D10CRACY]

"An easy failure, is the road to success...."... I like it!

[@janosnagyj.9540]

12:21 "Americanos nr. 1 defense against metric propaganda" I can't stop laughing :D :D Hilarious :D

[@steelcannibal]

Made me laugh out loud as well! Love it!

[@MatthewHolevinski]

sweet jesus me either, i need air

[@jhoeaying6165]

Hahhhaha. Love it dude..😂😂

[@wakeupgeoff]

Mate I love the journey you took me on. I was devastated seeing that last tooth! Cant wait for the next iteration.

[@willc5979]

Spoilers bro

[@CandidZulu]

Seriously dude, this is video art, its above and beyond instruction on a very high level! And the humor is just awesome!

[@BlackBeardProjects]

Ahah! I swear I was watching carefully but I wasn't understanding how the hell it would have worked. Only at 10:08 I started to get it. Lol. How smart! Epic video mate, love the edit.

[@GeoffreyCroker]

Cheers Black Beard!

[@scottcates]

When outvolute teeth are called for.

[@TheMetalButcher]

So... use a rack on the sample gear for both the indexing and the locomotion. Those wires are part of the issue. The shaft should have some ability to slide, so you can slide the shaft and sample gear out, rotate it one notch, then mesh back into the rack.

[@peterfitzpatrick7032]

That sounds like a plausible concept !! 😎👍☘️

[@cjc1216]

Great minds think alike sir, i just wrote something very similar and then found your comment lol. Hopefully he sees and gives it a go

[@DoktorHalloween]

Was checking to see if someone else had thought what I was thinking. You wrote it so much better than I would have.

[@ReiniGrauer]

This is exactly what I was going to post. You could even have the rack on a hinge, spring loaded on top of the spur gear. To advance, lift the rack, rotate the part, and drop it back down. As long as the rack is parallel to the table, your locomotion and indexing should work fine. This would also let you change out the spur gears you are duplicating without having to mess with other parameters besides the height of the hinge.

[@jgt9261]

The rack meshing with the index gear will work very well; however, to cut any gear you would always have to have an index gear with the same number of teeth as the gear to be cut, and the same DP as the rack. Indeed, with your present set-up you need an index gear with the same number of teeth as the gear to be cut, albeit that it can be any DP or module. I think slipping of the wire drive induced by the cutting process is the problem, combined with the accuracy of the diameter of the wheel being driven by the wire. Perhaps have a few more turns of the wire around the wheel, and an index mark on the wheel and wire to ensure that they returns to the same place after the completion of each tooth. The diameter of the wheel, and the thickness of the wire need careful consideration and accurate measurement and maybe some trial and error.

[@beerdeliveryguy6265]

I had to pause the video to askjeeves what a bing was. Turns out its a lot like a dogpile

[@felderup]

some of us actually use dogpile.

[@MatthewHolevinski]

@@felderup alta vista isn't aware of that

[@felderup]

metacrawler would remember.

[@MatthewHolevinski]

@@felderup okay show off :) to be fair, i spent most of my time searching with veronica.

[@felderup]

i started on the internet late in my life, so metacrawler is about as far back as i remember actually using. it was right around the time that slackware could still be installed from floppy disks.

[@Qardo]

So Jimmy. What did you do over summer break? Jim: Made gears. That is nice. Jim: On a Shaper. *Surprised Pikachu Face*

[@jimc12]

Glad to see an update! Can't wait to see the rover complete.

[@forrestaddy9644]

The process of generating involute gear teeth involves a formed cutter representing a single tooth of a meshed rack translated in synchrony with the blank roll at the pitch diameter. The Fellowes gear shaper worked via this principle but used a rotating cutter, itself having a generated tooth profile. I'm quite sure many a machinist passed the time watching long cuts musing the problem of making generated gear teeth with simple apparatus. The magazine article you referenced illustrated the tight band method but some improvement could be made - specifically indexing. Instead of returning to a reference location to index the blank (setscrews may move the hub relative to the shaft when tightened), I suggest you re-arrange things on your arbor. Pin the pitch diameter drum (the part the wire attaches) to the gear you're using as an index reference. Allow the drum/index assembly to rotate on the mandrel. Mount a hub with a shot pin that engages the index tooth space and lock it to the mandrel. The procedure: cut a space, traverse back to the starting point, pull the shot pin, rotate the mandrel/blank/index one increment, re-engage the shot pin, cut the next space, etc. The wire has elasticity suggesting it's stretch may affect the cut profile at varying engagement. I recommend the shortest possible distance between wire attachments - or a ribbon in lieu of a wire cable - or both. And leave finish stock. A light final cut will be less affected by the wire's elasticity. I suggest you acquire a gear tooth caliper. The old school vernier gear tooth calipers are still to be found but are expensive - in the $300 to $800 range. Import digital gear tooth calipers, while (yuck!) imported, work quite well in my experience. Heres an Amazon link: www.amazon.com/Machine-DRO-ME-CAL-GEAR-25-Digital-Calipers/dp/B00DS9IGQA This tool, though expensive, will enable you to grind your tool to the desired tip width and cut the tooth to width at the pitch diameter - and they have many other uses. The alternative is measuring pinswhich are not only more accurate but metrologically definitive. However, some study and calculation is involved in the use of measuring pins. Drill shanks of equal size may be substituted for gear measuring pins. There are formula for calculating compensation to be used for non-standard gear tooth measuring pins. Consult the Van Keuren Catalog #36. It has more formula for calculating measuring pin data than you really need to know but I reference it for the readers who delight in arcana. Gear cutting is one of the most technical tasks for a machinist. Anyone can chomp out a gear looking thing that may or may not mesh with a mating gear. But if accurately cut gears are to be made, a certain amount of book study, vocabulary assimilation, and calculation will be necessary. The Diametral Pitch and Metric Module gear systems are highly evolved and standardized resulting in a cookbook simple method of calculating the manufacturing data necessary for gear cutting. My high school math teachers without exception made their topic cryptic, boring, and excruciating to me. I graduated hating mathematics yet a few years later in my apprentice training, I managed to understand and work the many formulas preliminary to gear manufacture. So, based on my example, the computational side of gear cutting is within the grasp of most anyone with a need willing to study. Your set-up demonstrated the principles and potential errors of involute cutting on a shaper perfectly.

[@peterfitzpatrick7032]

Nice post Forrest.. 😎👍☘🍺

[@NoelBarlau]

Having put far too much time into thinking about this type of setup, it always seemed like a mistake to me to ignore the diameter of the wire when making the pitch circle diameter blank. This blank would be theoretically "rolling" down the outer edge of the guide wire, which would make it necessary to take into account the thickness of the wire when turning the blank. Of course there are many other variables, as you said. But this is one variable I've not seen mentioned before.

[@gplusgplus2286]

Didn't understand shit but your authoritative writing probably makes the above 100% correct.

[@GeoffreyCroker]

A few people have got in touch telling me about this guy JB from OZ - including the guy himself - never met a shy Aussie :) - who has a video of this same shaper method. I haven't watched the video properly yet, but it looks the goods. Check it out if you're interested. kzbin.info/www/bejne/jn-ziY2dppx4asU

[@JBFromOZ]

Thanks heaps mate!! Gotta love a great shaper video

[@davidbrown8365]

JB From Oz also has good taste in four wheeled contraptions originating in the UK

[@JBFromOZ]

Thanks David! Referring to my Morris Minor Ute EV conversion? (E-Minor), the Daimler’s? Or the Austin Healeys? I do love my JCB Backhoe though, also could count! Glad you like them, plenty more content to come there too

[@thecoffeestainonyourcarpet6413]

hey are you okay Geoffrey? you haven't uploaded for over 3 months now

[@GeoffreyCroker]

Should be a batch coming in November.

[@userwkvw]

@@GeoffreyCroker Waiting your videos much more than a new Vikings series! Thx!

[@southyjd]

Yeah this is one of the only channels I actually go check for an upload as I'm worried I missed one ha.

[@Andrew_Sparrow]

@@southyjd same! :)

[@th3k1ngofchina]

Easily the most entertaining (and interesting) channel on KZbin. EASILY

[@tannerfriend7979]

I can't wait to see that Rover get done looking forward to the next part!

[@Preso58]

Great video. Entertaining as usual. I like your iterative approach to the design challenge. If only I had a shaper, or room for a shaper. But, since This Old Tony made it illegal to sell them I have no chance.

[@rickpalechuk4411]

I don't care what you think... I'm watching it twice. Cheers

[@mymechanics]

You're a genius 😮

[@GeoffreyCroker]

Hahaha. This is the least genius thing on KZbin!

[@blackstone3323]

@@GeoffreyCrokerHi Geoffrey, Eric from Adelaide here. if you have a spare gear that is the same as you want to make, cut it into quarters and take one of the quarters and use it like you used the piece of aluminium . have it so it slides along and into the gear on the shaft. It will be more accurate. i am sure you can elaborate on this idea. good luck.

[@magnumpunch]

Instead of wire you can use a rack to run the indexing gear on. Rack fixed to the machine (with screws). You will index and rotate at the same time. I love your work and funny storytelling

[@arrindaley3714]

I was thinking the same thing, as long as you could adjust the height of the rack it shouldn't matter the size of the heat your cutting, just the number of teeth. So you could have a set of three same modulus gears and rack and be able to chance teeth counts. It should index better because it would be an average of the teeth it's using.

[@SamuQu]

Timing belt maybe?, that being said, I think you're an artist, I really loved the lathe shots, the lighting, everything is perfect. And the humour, man, I was laughing or grinning the entire time. I worked the shaper for a while at my job, truly an amazing machine, I'm eagerly waiting for mk2, and starting to crank my brainshaft into how I could build a fork of this project.

[@MrEyad1990]

We missed you . Where are you ? Is everything ok ?

[@rebelba42]

11:54 This, the projects chosen and your authentic personality makes your channel top notch! Waiting for your next video is like waiting for a special present! Many thanks for sharing your great work with us!

[@AndrewReuter]

A hilarious noir machining video. Well done!

[@peterfitzpatrick7032]

Gittin trapped in the vice .... 🙄😂😂😂

[@hilltopmachineworks2131]

In part two you go buy a milling machine and some involute cutters. :) LOL.

[@michaeldenton8610]

Oof that last tooth! But in all seriousness you could have "flat gear" meshed with your indexing gear. So you slide the plate through the bottom of the round gear in increments to set your cut.... I'm tired

[@witzed1]

I probably don't have the best interpretation of gear cutting but...why not grind the tool to be the involute shape. Mount the blank on the indexer. Feed the shaper table up to a limit as the shaper cuts deep into the blank. I know this requires more accurate tool grinding but it eliminates the apparently error prone wire mechanism. It appears that you are trying to replicate how gears are hobbed (one tooth at a time) which would be more advanced than the first attempt of making gears on a shaper. For that matter, if this were being done for the first time where would the indexing gear come from?

[@MrEyad1990]

Freaking finally . Never missed someones voice this much .

[@georgenoe776]

I have read the same article and thought about it. I believe the article mentions using "piano wire" to drive the rotation of the shaft holding the gear blank as it is being machined. You did not use piano wire. Piano wire will be a single wire that has a very high tensile strength, that is, it does not stretch. One other setup I have seen used a stout spring to load the wire. If one looks at a piano one sees wires that are wound with another wire; the core is the piano wire; the winding wire just weights the wire to tune the resonant vibration of the particular note. Presumably the success of this method requires accuracy in the placement of the wire's center at the proper radius on the driven blank and "rigidity", that is to say, no slippage of the wire on the driven blank. Thus a rigid wire and taut constriction of the wire on the driven blank is required. Your effort was doomed to failure with your selection of the cable to drive the driven blank.I suspect a substitution of real piano wire, adequate loading of the wire tension and attention to the accurate diameter of the wire on the driven blank will give you a better if not an excellent result.If you really want to confuse yourself see if you can cut an accurate bevel gear on a shaper. There is a work around using a dividing head and offsetting the cutter to approximate a bevel gear. Apparently two such gears thus constructed will mesh well with each other. I believe that there is a method to cut a true involute bevel gear using a shaper but the rotation is controlled differently. I once found this method described in a patent application and believe it was used in a type of gear cutter.

[@hiddenworldforge374]

Use a gear rack instead of string. Attach it to the body of the shaper, use a gear on the table to drive it

[@CraigsWorkshop]

Here's an idea. Make an adapter for the end of shaper ram, that drives a crank that turns a spindle. Cylindrical grind a standard tool taper on the inside. Then you have a milling machine. Now all you need is to follow the existing instructions for making gears on milling machines... Really though - beautiful video making, an absolute inspiration. As for the indexing problem. I think if you look for and tighten up the inaccuracies of "the contraption", you'll do ok. I think you're on the right track and I wouldn't change anything major in your setup - just debug what you have. There is almost zero side to side force so solid levers will not be better than (potentially stretchy) cable. Just debug the setup, find the source of the error, I think. Cheers, Craig

[@peterfitzpatrick7032]

I think yer right Craig... superglue ? 🙄😂😂😂😂 EVERYBODY knows araldite makes a proper keyway !! 😏 😎👍☘️

[@CraigsWorkshop]

@@peterfitzpatrick7032 :-)

[@Nikkeftw]

If I was a really good review writer, I would write a long review about how awesome this video is with all its eeriness and effects. BRILLIANT! Im not even a metal-worker of anysorts, engineer or anything else related to it. I just have a general understanding and interest in these kind of things. Never worked machines like this. But you had me entertained and soaking up the content 100% of the time. 10/10 !

[@PiefacePete46]

@Bottleflask : Be careful... Be very VERY careful! Unprotected exposure to this type of content can result in your induction as a fledgling engineer! Then again, as you posted your comment three years ago, you are probably a fully-fledged engineer by now anyway. Have you made any interesting projects lately? You most likely qualify for the wall poster that says "A weak ago I cudn't evun spel 'Injunear'... and now I are wun!" Geoffrey's video captivated me too! 😵‍💫

[@Nikkeftw]

@@PiefacePete46 Haha, wonderful response. My title today actually IS Project Engineer!! I do work with a lot of engineers, but Im afraid I got my title without going to school as an actual engineer. I went down a automation programming path, and do the same work as several types of engineers do, but not the kind we are looking at here. So contrary to my original comment, I am indeed related to engineers now :D My last home project was making a spinning disk as flat as possible for my 100kg whiskey-barrel-bucket full of dirt for a literal tree, which is in my living room. As no one can stop me when I have a bad idea, I will say that getting the bucket onto the spinning platform ALONE, with tree in it, when it was done, was probably more of an engineering feat than making the "contraption" itself. However, I did indeed succeed, and wife lady was pleasantly surprised when she returned home. And I had bruises up and down both arms, but I enjoyed creating and assembling!

[@PiefacePete46]

@@Nikkeftw : It's interesting the paths our lives take... my son, who is in his late forties, has worked as a Programmer/Analyst since he left school. He has worked at the same desk for all that time, yet he has worked for six employers, in name at least. He has had more job titles than I can follow, including a recent one with the word "Architect" in it... he has never touched a drafting table, scale rule, or CAD program in his life... go figure! 😜

[@computername]

Engineering classes, gear pair calcs. Final result for output gear: 43.7 teeth. Perfection!

[@stamoulohta]

Man, I really love your videos. I so wish you could make more of them.. Cheers :)

[@dillongreaves9452]

Did he die

[@badmojamma]

The Kiwi accent is harder to decipher than Aramaic poetry, but this video is now one of my faves. Very thorough and professional. Good work, Geoffrey!

[@peter50555.]

Imitate a clock escarpment with ratchet and pawl on the original gear and a clock spring to turn the shaft... old school and simple. Add a second stop at some arbitrary angle on the opposite side of the original gear; the two stops engage a tooth alternately advancing rotation partialy with one stop setting the correct position as the cutter advances. Rather than completing one tooth at a time, you would be doing a partial cut all the way around; but advancing the table crossfeed would also complete all the teeth simultaneously. The motion of the stops could be actuated by the motion of the cutting head. Within some limits the original gear could be substituted to create copies with different pitches.

[@zukowski2023]

Awesome job for taking a wild assed dive at it! I am looking forward to see the "next step". Good Luck! Great videos by the way! ( P.S. I think "Tony" would be impressed, know I am..)

[@eformance]

I sure hope you're not a dentist by day, I'm not sure I could stomach a smile that looked back at me like that half missing tooth! :-)

[@GeoffreyCroker]

Hahahar

[@EverettsWorkshop]

Rustinox shared this with me, and I'm glad he did! I had never heard of this method until he shared a copy of that Model Engineer article with me and sent me your link. I've been wanting to learn gear making and it would be even cooler to make them on my shaper, so thank you for sharing your experiences and results. Nothing was ever perfect in the first run, I learned a lot from what you shared here, thanks for doing that!

[@bearsrodshop7067]

what make is yours?? The Klopp 450 purchased Nov 25th 21, will be at our shop on Dec 4th,,,Going be watching all about shapers , and subscribing to others that own them (@@). Bear

[@victoryfirst2878]

What is the manufacturers name of the lathe tool holder??? How does that compare to an Aloris type ??? The shaping of gears on a shaper you started needs two improvements. First the use of a rack and pinion near the throat. Second the use of a dividing head on the other end. This would work perfect. But the time to cut the gear will not make you money for sure. Good day too. VF

[@michaelhayward7572]

This is good. Not heard of this channel before. Subscribed. I'm in the process of making a 40T gear on my Boxford 8" shaper using a H/V 6" Vertex Rotab. DOC will be the trickiest bit i reckon. Wish me luck. That Viceroy looks like a modern squared off version of the old Royal / Alba / Elliot 10" shapers. Regards, fellow shaper freak,

[@ljkkj2511]

hey mate, what about the Land Rover?? ;)

[@vitezizsrednjebosne1596]

I did same job but I take a old geer and cut a piece and weld o shaper tull and get a angel wrajt emidietl...pozz ppn vitezovi hello from Bosnia and hercegovina

[@TBendez]

Really knocking it out the park with the editing Mr. Croker!

[@DanielBelzil]

Wait. You have a lathe? Not a machinist, but seems like you should be able to cut gears on a lathe? Love your channel by the way.

[@89RASMUS]

Interesting project. Replace the wire and wheel for a rack and pinion and I think you will have a greater chance for success. And perhaps integrate the dividing mechanism into the pinion as well. A simple way could be to have the axle running freely inside the pinion and have the corresponding dimples, depending on the division of the manufactured gear, drilled into it and a locking lug on the pinion to engage into said dimples. If you use the same pitch and module on the rack, pinion and gear to cut, I guess you could just step the pinion over for indexing.

[@JesseSchoch]

I just released a video on the topic of calculating the tip width. I made a python tool that automates your advanced simulations which you may be interested in if you try this again. Thanks for this video, it was inspirational and funny!

[@GeoffreyCroker]

Cool. I'll check it out when I get a chance 👍

[@fa_ek]

What about using a rack and pinion instead of steel wire to roll your workpiece (and some spring to avoid backlash)? Great video, congrat.

[@skreech01]

I got some Chernobyl flashback from the radiation sounds

[@ogaugeclockwork4407]

The cutter geometry just needs to match the profile of a tooth on a matching rack. Thats the basis of this method.

[@BokorRider]

somewhere in another country i have an old book maybe from the 1960's "The Amatures Lathe" bt LH Sparey.. in that he shows how to cut gears using a milling attachment on the crossslide of a little old Myford lathe its a great old resource if you can find it anywhere !

[@RickSolid1]

Page 332,427 is one of my favorite pages!

[@mjallenuk]

Uncanny ... When I was 11 page 3 of The Sun used to be mine.

[@peterfitzpatrick7032]

@@mjallenuk Samantha Fox.... Mmmmm ! 😍😂😂 😎👍☘️

[@dfross87]

It's amazing -- that book didn't look more than 310,000 pages thick.

[@kooldoozer]

How can 100 people give a thumbs down?? I am an engineer and a machinist and I learned a lot from this video. Thank you for making it.

[@cryoine7194]

they fell for the metric propaganda, notice the nice round number divisible by 10

[@MScholtz]

Rack and the gear you're cutting to rotate on it. Spring loaded to disengage and index.

[@connorbesson488]

I know his production quality is great and takes time, but I wish I could see more ahahaha

[@Fr1day-RT]

I've seen that tolerance stack up happen on a CNC indexer. They engineer rounded the degree on the on print. The indexer was a brand new replacement with a different style controller then the previous one. So we typed in the print degree and started running. It had roughly 100 2" long slots in it. After 2 hours of running and everything looking good I got the exact same result. It was not a good day. Great video.

[@hinz1]

Gearing down the leadscrew would be the best option for gear rotation. Very complicated, but probably how it's was done on gear shapers before gear hobbing and eventually CNC machines were invented.

[@blue03r6]

And young people think everyone was dumb back when that book was written. I honestly think people back then were smarter than people today

[@christopherwarner3]

Hoping all is well, channel has been quiet and we're looking forward to another build video 👍

[@bryce6713]

Perhaps some research on the Maag gear shaper would help. This is a brilliant attempt at the method you have done. I work in the custom gears manufacturing industry. I'll be following along.

[@MrEyad1990]

Man are you ok ? You still alive ? Wee really missed you .

[@bostedtap8399]

Excellent engineering at its best, and sadly worst, looking forward to V 2. Thanks for sharing and best regards from the UK.

[@machinist1337]

I love the video, I love all the great comments about how to improve on your design. me personally, I would have used the shaper as it was intended. grind/buy a gear cutter that you need. without a shadow graph it would be very hard to precisely match the grind needed. buying the proper cutter, mounting it to the spindle you made and taking .020 step downs from z until full depth is reached. then rotating manually to the next tooth and repeat. they actually make gear cutting heads that you can mount to your planer. they have a series of graduated dots and you turn a handle to get you exact rotation need for next tooth. anyways loved the video anyway, single point radius cutting on a rotation is pretty cool.

[@sheep1ewe]

Great video! Yes, this is indeed the reason why there so often are at least one of those old shapers left in a corner of even the most modern metal workshops ;) Unfortunatly i cannot realy help You but i think something that can lock a given position for each turn possibly would help...

[@gh778jk]

Bing? You want to have your viewers to have a stroke? Also, I suspect you don't own a Rolex..... Hugs! Paddy

[@theonetheonly2098]

Yeet

[@notamouse5630]

A rack and pinion with a set travel length and a lifter on the rack side can reliably replace the wire provided that a preload to one side is used to prevent backlash. The Lifter could also do the rotate after travel mechanism and the slow rotate mechanism using limit switches and a pair of small hydraulic cylinders connected with valves and a pump to alternating between aligning teeth and rotating mechanism while cutting.

[@paweisyn7446]

Hi, I just bought such a machine :) Almost a week has been standing still not unloaded from the car :( Regards from Poland , Paweł. P.S. What I could, I left on your interesting channel;)

[@pouyan225]

Loved the video! cutting gears the old-school way is super attractive to me. somehow it's very trendy nowadays to make everything super complicated and pretend as if it can't be done without thousands of dollars of precision equipment. but people did it back in the day using rudimentary tools and sometimes with better results than what some achieve using fancy tools.

[@PiefacePete46]

@Pouyan : The more I watch modern machine tools perform digital magic, the more I am in awe of the craftsmen engineers of old!... how did they achieve those things?

[@darthvader5300]

In the old days we do not use computers. We use an abacus and a slide rule! With them we were able, in our younger years, able to calculate the precise angle of the curves of the shaper's cutting tool bit. Go back to the old books on Simple History Of Machine Tools. A Short History of Machine Tools Hardcover - 1966 by L.T.C. Rolt (Author). YOU WILL GET ALL YOUR ANSWERS THERE!

[@darthvader5300]

A shaper is cheaper, dependable, reliable, and easy to mass produce and IT IS ONE OF THE FEW MACHINE TOOLS USED TO DIRECTLY AND INDIRECTLY MAKE MACHINE TOOLS, ONCE YOU HAVE THE KNOWLEDGE AND SKILLS AND EXPERIENCE TO DO IT RIGHT.

[@jameshanoomansing1442]

you are very skillful....well done

[@whitneyranchproductions4637]

Like Rocko (Rocko's Modern Life) made a guest appearance on The Red Green Show. Episode #31 "Anybody can make gear teeth". I sent this to all my fellow engineers (the ones with a sense of humor). 10/10

[@wetdedstuocm]

Kudos to you for making this work.. Waiting for the follow up.. Peace

[@orionfleming6783]

I subscribed as soon as I saw the shaper. It got way better after that, you sir are a legend

[@jacquesmaurel]

Congratulations for your video, could you please say me in which issue of Model Engineer was the article about gear cutting with a shaper, thank you.

[@growingknowledge]

Bing - I laughed out loud ! Been too long Geoff - stop having a life and focus on your youtube videos ! (Also, have you seen David Richards channel ?)

[@kevinmartin7760]

The problem might be that the drum (with the wire around it) is slipping on the shaft a bit. I expect that the cutting force is not symmetric and is trying to rotate the blank a little extra on each stroke. Hmm, that doesn't make any sense since your indexing disk (the gear) and blank are both glued to the shaft. I didn't get a good look at how you reset the side feed after each tooth; if you use the indexer to set this and the drum were slipping a bit your teeth would drift sideways (rather than around the circumference). Do the teeth you cut gradually lean a bit as you work around the disk? It probably would not be a visible effect as the tooth would only be leaning a few degrees.

[@darrenconway8117]

instead of using just one cable, try something like 10 or twenty. All laid side by side on the same cylinder. Multiple cables will increase stiffness and reduce errors. Tension a pair (loop) of cables from one end only to wind up the pre-tension.

[@Tachikomaster]

So I found this video in my recomended-s after some research on Klopp shapers.. finally something google algorithm got right! Anyway, nice piece of editing, especially love the sounds!

[@GeoffreyCroker]

Cheers 👍

[@c.j.1089]

Exactly how I expected my first gear cutting attempt to go! As I was watching you make the guide to fit into the gear teeth, I thought it might be a lot more accurate if your tool did not seat all the way into the teeth. You should cut an angle that is shallower than the depth, that way it will exactly find the midpoint every time. It might also be a good idea to load it with some spring tension.

[@MrDexter9i3]

Instead of the wires, use a rack on the bottom and maybe the pinion (on your axle) should actually be the actual gear that you are copying. After one cut is done, simply return to start, lift the gear and skip one tooth. Repeat.

[@sharetheblame]

I’m a true professional. Here’s a picture I downloaded from the internet. 😂😂 this guy.

[@hagki]

maybe he doesn't have time

[@sdunca4864]

LIke it- Bravo to you- in a style of "This Old Aussie" HA!! Seriously- Bravo! And the anti-metric propaganda will continue... Ever think about the 2 button method of making your cutter? Loved the vid- I like it without Arduino and the electronic whiz-bangs! And JB is a good fellow to watch- but seriously- do your thing and keep on going! Bravo again! From the land of the NON METRIC-

[@bloodreighn]

New Zealands very own metal machining Channel , GREAT!

[@one1shot1shaun]

Whats happening with the Landy

[@therealjamesmartin]

Pretty sure the wheel diameter with the wires needs to match pitch diameter no?

[@andyclarke9926]

I loved this video. I have 2 shapers (Bit greedy!!!!) I am looking at designing a jig for producing the required rotary motion using a rack and banjo gearing. To save time I'm going to use the change gears from a Myford. Any ideas would be great. Over the years I have grabbed as many books on gears and gear cutting. The best of these is "Manual of Gear Design" by Earl Buckingham.

[@MrButtonpresser]

At the beginning I was "what's this old tat? After 3 minutes I was riveted to the screen and had to know more...

[@andyvan5692]

great idea, and anyway, watchmakers made gears by only slot cutting, the "shape" is made on a special filing machine called a 'jacott tool', this is just a lathe like holding fixture, to index the slots, and you manually file the shape, like dressing a chainsaw chain, SAME PROCESS, just a different jig to hold the part/ guide the file!!- also the name of this process is called "topping" the gear teeth, for refference.

[@theelectricmonk3909]

NICE solution.... but prone, as you show, to compound errors. I think you could do away with some of the moving parts, if you make a multi-tooth cutter.... on the shaper natch. So... using your existing rack cutter, put some suitable tool steel in the vice, and cut a short rack, 3 teeth should be enough (but be warned - I used the back of an Inland Revenue envelope to do the calculations, and as we know, when tax is involved, numbers dance to their own tune). Put this cutter in the shaper, exactly vertical. Using your "spindexer", set up the first cut using the downfeed, go full depth. Retract, rotate one tooth, repeat. Continue until done. The idea here is that the angles are put on each tooth by the cutters either side of the middle cutter, rather than by the blank rotating under a single tooth cutter. Yeah, you end up with an approximate involute again, rather than a lovely smooth one; but that's nothing that time, and a lack of grease, won't fix...

[@ScottHammet]

Somewhat disappointed there's not a comment from @This Old Tony hiding in here somewhere, revealing the magic answer. On a side note, the KZbin algorithm recommended one of your videos based on God knows what. Delighted to have found this channel, as the presentation quality and humor are first-rate.

[@bpark10001]

A setscrew is not nearly good enough to prevent slipping of the cable/drive wheel on the shaft. That should be pinned! Your link scheme (only 1) should work as long as you keep the extent of the arc short & the fittings TIGHT.

[@GaryT1952]

BRILLIANT ! ( and oh so entertaining)

[@steveuphill3795]

The concept is a good one, but your method of indexing has caused culmunitive error. This is apparent at the end when some teeth show signs of being thicker than others. One solution would be to have the bobbin with the wire drive a slide fit on the shaft and have an index hole. In front of that another disk fixed to the shaft but drilled at a pitch circle for the number of teeth required, (needs accuracy) then index with a pin the disk to the bobbin for each tooth.. Either way this method requires a new bobbin and new disk for each different gear blank. Well that looks like one possible answer anyway and it negates your setting up each time with a clock. Enjoyed your land rover rebuild no end, great work. Steve

[@MrBuck295]

BACKLASH now that I have your attention you need to eliminate backlash you have the backlash introduced by the piano wire , then there is the backlash introduced by the gears that drive your table ,I noticed you have to manually advance the table part way to compensate for worn drive then there is the backlash introduced by just going back to one set starting point ,even if you use an indexing plate you only advance it in one direction if you go past you don`t just roll back to the indexing point you have to roll past it then advance to the proper point you need because of backlash ( if you have watched any one who used a mill with an indexing plate you will see they do that ) it`s cumulative you have to eliminate it

[@timothyearp631]

Hmmm. This method is the hard way in my opinion, but if life were easy you would own a gear hob machine. You need to limit the possibility for error and eliminate the possibility for your errors to stack up. Also something that is desirable is a way to make gears with a number of teeth that are different than the gears you own. My first thought is to ditch the cable system for a rack and pinion, but with an added (removable) idler gear to create a shortcut way of indexing your part --- You might even be able to work out how to create different teeth numbers by simply using a different ratio between your idler and the gear turning your part.

[@hashemmatter5389]

Hi Geoffery , Is there a group over there in NZ where you get together with like minded individuals you know to mess about with machinery , tools and all the hobbyist stuff that you cover. I cant seem to find anything here in Australia and just wandered if you guys did it better across the ditch :) >? Great video BTW love the outside of the box thinking

[@celtic1522]

Yep, there are heaps of older fellas in New Zealand who are exiled to the shed with their cats and machine tools by their old trouts! Or they just hate their families and prefer their sheds and cats company! We call them the Model Engineer Clubs........

[@hashemmatter5389]

@@celtic1522 Oh wow i WISH there was something like this in Sydney I would be there in an instant (away from the whinging wife) :)))

[@celtic1522]

@@hashemmatter5389 I am pretty sure there are a few model engineering clubs in NSW, aim for your nearest small gague railway track which has model steam engines running upon it. On facebook try Sydney Society of Model Engineers, that would be a good place to start, they have a track in Sydney somewhere!

[@hashemmatter5389]

David Edmond thanks I’ll give that a try would love to get into it

[@peterfitzpatrick7032]

At the start , u say you'd need a different cutter for every tooth-count ... but.... the standard involute cutters are merely rotary form cutters & are acceptable for a "tooth range", so your form tool should be the same ? That reduces the number of cutters you need significantly... 😎👍☘🍺

[@truthseeker1623]

Total and utter brilliant love your logic or ...but your mind will find a solution as errors are there to help us find solutions. GREAT STUFF.

[@robertpartsmade5832]

Sir , as always informative and expertly executed it is sometimes a bumpy road to success!! Brilliant way to start a rainy English summers day here in the 🇬🇧 Regards Robert Partsmade