Metal Planer Restoration 39: Making a Bevel Gear Blank on the Metal Lathe

[@greaser5691]

I'm not a machinist, so I was happy that I had decided the bore would be cut as the 'reference surface' for the remaining operations before you said so (it shows I am learning something about things, like order-of operations, from watching channels like yours). Greetings from down under, I trust you and yours are keeping well.

[@robertbamford8266]

Don’t you find that Keith ALWAYS does that? I think of a question I would ask and ... it’s answered.

[@MikeBaxterABC]

If you didn;t have a set of fancy mandrells, you could just turn a light press fit spindle to hold it, with a drilled and tapped end to tighten it down.

[@alan-sk7ky]

Of course, if he had used bar stock steel it would have been a 'from one end only' operation (apart from parting off) [ 24:45 watch that springy setup screech] but no, Keith wants to be authentic and reset at least twice let alone having less to grab hold of when gear cutting.

[@SciPunk215]

So much great information here! I breathed a sigh of relief once the back cut of the bevel was made. As soon as that was done, I knew there was enough material to get this done perfectly. Maybe other people saw it earlier, but that's when I was convinced.

[@zahnledl]

I'm not a machinist but can sit for hours binging in your work and videos. Thank you for the entertainment and fine post editing.

[@travelingkaspersworld4096]

Same here. It is calming like watching fish swim .

[@OscarSommerbo]

I found this video incredibly rewarding to listen to, it was quite easy to hear the interrupted cut when Keith was cleaning up the first two surfaces.

[@izzynutz2000]

come to think of it, I don't ever think in all my years, if I've ever seen a bevel gear manually cut?..🤔 I'm so glad I watch your channel Keith..🤓

[@CHICOB4261]

Mr. Rucker I think that’s one of the finest pieces of work that I’ve seen you do I truly enjoyed it! I was very certain from the beginning that it might not work but I thought if this can be done you will be the man to do it. Thank you I can’t wait for the next part!

[@oldpup2182]

Reminds me of machining cast oil field valve bodies. Never really knew what we'd wind up with until we started getting at least close to final dimensions. I like the way you think through the different processes. Thanks for the video.

[@Landrew0]

That's why Keith is such a wealthy man. He knows how to think.

[@carloscordero4204]

Wow glad the casting worked Clarke will be happy! Looks nice . looking forward to the rest !!

[@ypop417]

Well Done Keith. The next one will be a learning experience for a lot of us

[@johnquinn3899]

Wow!! Get my notebook out. What a lot of info today. Thanks Keith

[@danhei]

You would be a great instructor. I worked with leather, now retired, but love to watch and learn people work with other materials. Thanks for these videos.

[@johnwinden8511]

The interest that I had in watching this video was exceeded only by the amazement of your unlimited skills and abilities. Very good video, thanks, John

[@ralphsmull7049]

So satisfying to watch pieces being made from rough castings. The sense of accomplishment is one of the finest feelings to have. Please continue to keep at it, and I'll be watching this series for my own satisfaction!

[@bufford14]

That's exactly what you should do. I love to watch you work on old machines. Thanks for what you do with this channel. God bless you.

[@rickpalechuk4411]

Looking forward to seeing you cut the gear teeth. This has been a great series, thanks for sharing. We really appreciate your efforts on this. Cheers

[@clydebalcom8252]

You remind me of my grandfather. He never met a machine he couldn't repair. His drive to learn was legendary.

[@dfishpool7052]

Hi Keith - I was impressed by the way you machined that casting - not an easy job when you know that there's not a lot of material to spare - great job.

[@carolcarola9719]

I agree with your prototype approach.

[@ccrider5398]

Nicely done. It doesn't look like you ran into any voids or hard spots on the casting. That's a plus. Looking forward to you cutting the bevel gear. The fact that the teeth are wider at the larger diameter than the smaller, seems like it would be a tough. I think of the challenge of doing that when the planer was originally made. Your equipment would have been something they could have only dreamed about!

[@RRINTHESHOP]

Well done Keith. Good idea on the Delrin.

[@MrPatdeeee]

Is it not a blessing to see this genius do things that make a very hard task look easy? WOW! There is no one like our Mr Keith Rucker. May Jesus continue to bless and gift him to be able to do things that are incredible; and then share it with us. WOW! Thank you kind Sir.

[@michaelgamble296]

I was pre-deciding right at the start the way you would tackle this interesting job in the Lathe. "he'll use a mandrel" and you did etc. Most enjoyable. That was some close tolerance in the rough casting! You have a good casting man there! I was with you all the way! Thanks for sharing.

[@wazzazone]

Mr Rukker love your work, I find the turning ABSOLUTELY amazing. Thanks for sharing!!!

[@TomTalley]

Like the sculptor says when looking at a block of grannet, "it's in there somewhere, all I have to do is take off all the stuff that doesn't belong."...nice work. Thank you for going to the trouble of sharing it with us.

[@stevenslater2669]

I worked in the product engineering side of a Big Three car company’s Engine Division. We designed and built prototype engines. Our Layout & Inspection Department used layout fluid (Machinist’s blue) by the barrel! The gear blank that Keith machines here (& the Fireball Tool plate that Abom79 just machined) are simple enough to eyeball for finish stock condition. But a big V8 cylinder block casting with many cores - you have to put the raw casting up on the surface plate and go back & forth between the crankcase to the water jacket cores to the cylinder bores to the head decks to equalize the casting for core shift. It wasn’t unusual to get halfway thru & discover you didn’t have sufficient finish stock. Paint over all your carefully scribed layout lines & start over. Our best layout inspectors could lay out 2 blocks in a day. But sometimes, especially first castings for a new program, took several days - and a half-gallon of blue! I really enjoy watching Keith & Keith & Adam & Tom machining manually. That’s what it was like when I started my career at the Big 3. We started to switch to CNC machines in our experimental machine shops by around 1969. Seems like yesterday, but it’s 50 years ago!

[@ThAtGuY-u9d]

When did you start at the company and what department did you start? Sounds like you have some good stories about how complex parts were machined before the days of CAD. Something that’s fascinating to me as I’ve been rebuilding old ornamental machines from before they had all the computers and it amazes me how good they were then.

[@MrValhem265]

Which big 3 COMPANY Steven Ford GM Chyrsler?

[@Frank-Thoresen]

Thank you for making your work logic for us who are novice in machining. I have used a lathe but that was in school days. I became a metal worker and love precision work.

[@Curiosity-NZ]

The problem for us old school engineers is that we never can stop learning. The young one's today just understand us old guys down on the shop floor, we mostly either learnt it on the job or worked it out as we went. The next part of this bevel gear machining operation will be interesting to watch.

[@The_DuMont_Network]

ROBERT: -"The young one's today just DON'T understand us old guys". Moreso they DON'T WANT TO understand us old guys. "Put it in the CNC machine, set it and forget it"...

[@DavidKutzler]

Great! Now I have bore micrometer envy. Thanks Keith.

[@SunnnyDay]

Really nice work there !!

[@prodoverjeff2876]

For all my years maching, I have never made a gear or used a dividing head. I have a little understanding of the math involved, but I am sure you have found a level of math I have not even thought about. I just noticed the date of this vid and will look for the next part of it or I;ll be waiting for it to show up. Interesting stuff!

[@jmrico1979]

we're getting close wih the planer! anxious!! let's cut some metal already!!

[@CRUZER1800]

Another great video, Keith...

[@elsdp-4560]

THANK YOU...for sharing. Very much enjoyed.

[@tonywatson987]

Thanks for that, Keith. I was wondering how you were going to approach the cutting of that compound angle on the teeth; good idea to use Delrin as the practice piece, so much could go wrong, you don't want to screw up that casting! Looking forward to the next step.

[@joeestes8114]

Awesome video! Thanks for sharing!

[@CraigLYoung]

Thanks for sharing!

[@PixelSchnitzel]

Oh man, I always forget that I can do what you did at 23:45. Thanks for the reminder!

[@sharkrivermachine]

Having never cut a bevel gear myself it is going to be interesting to see the set up. I understand the theory now to put it into practice.

[@roysmith3198]

I see your over here learning also :)

[@allescncmachine5002]

We also have a similar video, and look forward to your watching our video！

[@williamchristian2361]

Really enjoy watching these videos brings back old memories I was a machinist for 37 years

[@jamescopeland5358]

Good job Keith

[@mikecabe6127]

Another great teaching video Keith..........Thanks for the lessons!!

[@westsideflyer7559]

Work: I just love to watch someone else do it! It's fun to see the part emerging from raw stock or a casting. The processes involved are better understood when the process can be seen. Thank you! I enjoy it!

[@bulletproofpepper2]

Thanks for sharing. Great work!

[@Nicholas-qs7ds]

You're a good teacher the best I've seen thank you so much

[@JamesDedmon]

Neat work, what you need is a bevel gear cutter. My first machine shop had 2 of the larger Gleason bevel gear cutters, these was really old machines 1920’s vintage. That shop did a lot of textile parts, so a lot of bevel gears was used, that was typical cast just like your planner

[@dionpeek4339]

Thank you for the demonstration

[@robertbamford8266]

“The easy part is done.” Haha! Great video as always. Looking forward to watching you do the hard part.

[@fredbloggs4829]

Wow, was that satisfying. To see the rough cast iron turned into a neat gear blank. I was sure there were going to be voids left, but it all came together in the end. Great video.

[@nevetslleksah]

Nice work. I have never tried to cut any bevel gears either. Looking forward to future videos. Stay healthy.

[@billstoner5559]

Keith, another fine video. I can’t tell you how many times I’ve made prototypes out of “cheaper” material to get the process down. I’m not a metal guy, but carve wood. Keep it coming! Thanks.

[@shawnmrfixitlee6478]

Great share Keith ENJOYED !! Great call on the delrin !!

[@jerrycoleman2610]

Keith, Awesome video. I’m looking forward to your next video on cutting teeth on this bevel gear, thanks for sharing your video.!.!.!.

[@tomthumb3085]

That’ll be a video worth watching. The setup and cutting angles are a great subject for a video, involving some really interesting tricks. I’m looking forward to seeing it. Thanks For another interesting project.

[@Rspri10104]

I'm looking forward to the next step.

[@jwaterous224]

This was fascinating because of the seeming one off dimensions and the well thought out cutting plan you executed perfectly. Soon the machinist community will be sending you all their bevel gear cutting jobs. Was anybody else staring at the Scotch Brite on the shelf?

[@johnfleury5430]

As usual you're a master take care be safe

[@wolfitirol8347]

Thank you for sharing and explaining to us hobbyists 👍🤠 i love your kind of working and solving problems ..😎

[@ChrisSherlock]

A good result there Keith. It is always tricky to access an irregular blank to see if it actually contains the finished product you are looking for.

[@piperjohn_3]

Nice save! Learned about some new techniques on this one.

[@MikeBaxterABC]

Great job!!! ... Good saving that casting! .. Well worth the effort! :)

[@FredMiller]

Great segment Keith. I don't think I have ever seen a bevel gear cut on KZbin. Good stuff! Stay safe...

[@qchriste]

I never realized how much my OCD dislikes run out. My eye was kind of twitching until you ran the last couple of passes on the last taper and eliminated the last of the casting roughness.

[@izzynutz2000]

don't feel bad when I first started watching these machining processes the people were putting up on KZbin I was blowing the chips out of the way 😆😆😆

[@bme7491]

Yeah, you could see the light flickering on the casting as it turned telling you there was still some rough surface to remove.

[@johnchristopherrobert1839]

Exceptional presentation, great content

[@assessor1276]

This is a very interesting piece of work Keith - nicely done!

[@lacarambacaramba]

Watching his videos is so relaxing that I fall asleep 🤣 😅 I enjoy every video he makes, even though sleepy I still learn much about it, it's a a shame I don't have a lathe machine, thank for teaching us, regards from a fan

[@MaturePatriot]

Doubleboost would call that a Bell End casting. Glad you were able to get a good blank out of the casting. Waiting on the gear cutting. Nice work.

[@chieft3357]

Yep, I do the same thing with Acetal rod when I cut gears for racing gear boxes. You got to make sure when you cut a gear. Stay safe and healthy.

[@onebadsavage26]

Waiting anxiously for the next installment. I have a bevel gear blank sitting on a shelf that has been there for years...chicken to wreck it cutting the teeth. Maybe now i'll try it...after you knock one out

[@disalhaputhanthrie617]

great work...!!! looking forward for a detailed bevel gear cutting....!!!

[@ndoghouse6853]

Cutting bevel gears has got to be fun! I want to see that! Subscribed and waiting!

[@RizwanShaikh-hs6gt]

Good job sir 👍

[@dananelson1801]

Thanks Keith, reminds of the one I used in high school. Looking forward to next video.

[@victoryfirst2878]

Hello Keith, just like your way of sneaking up on the dimensions. This will work out just fine. Keep up the great work too. VF

[@victoryfirst2878]

I have cut bevel gears on a milling machine, Sunderland gear planer, Cincinnati shaper, and a lathe too. You have many options Keith. Am sure you will make a great gear. VF

[@victoryfirst2878]

@chris0tube I am just amazed to this day how a simple machine can make so many different gear types with super accuracy. Cutting herringbone gears is what I remember most. The largest gear I remember cutting was six feet in diameter and helical. Smallest was two inches spur for an old milling machine, do not remember the make. Great machine too. VF

[@victoryfirst2878]

@chris0tube Making gears is a very soothing job. The part that I hated was the smell of the high sulfur cutting oil. The rest was just gravy. I do not remember the machines number designation. But cutting herringbone gears will be with me forever for sure. Good day and peace too. VF

[@victoryfirst2878]

@chris0tube I certainly agree those memories will be with me to the end. And the young machinists do not have a clue how just simple math can do so much. They need a computer or they are out of luck. Good day to you Chris and cheers mate too !! Peace and out. VF

[@bobbyvance6622]

Braze the teeth on the old one to practice and you will have a spare gear. That will help you in you setup as well.

[@kevinriese6384]

great idea. It would help.

[@gorillaau]

Probably not a bad idea.

[@screensnot]

Probably never need a spare gear, so repairing it would probably be a waste of time. And if you think it would work after you repaired it, you would just stop there. No need to make a new one. Using the old gear to help your setup to make a new gear is a good idea, but doesn't need the repair job.

[@jrondyer1049]

I was wondering if that would work? Will the chipped teeth at the end of the gear sustain the stress?

[@csnelling4]

Great job, looking forward to the tooth cutting video Keith 👏👏👏👍🇬🇧

[@danbreyfogle8486]

This is a very interesting part of the project and I look forward to seeing more of this work.

[@bazzaf246]

Can't wait to see the planer in action! You're going to be able to restore anything all in house soon 👌😊

[@steveshoemaker6347]

Better late than never...Thanks Keith...!

[@dannygreene4594]

Looking forward to the gear cutting Danny. Gisborne New Zealand

[@freddupont3597]

That would be great to post a video showing the learning process cutting the plastic gears.

[@kerrygleeson4409]

Great job Keith 👍🇦🇺👀

[@Just1GuyMetalworks]

Ahhhhhh, bevel gears 😊. I did mine in two cuts, but I suppose depending on the amount of gap between the teeth on the heel you may need a third down the middle to clean it up. I've actually cut two bevel gears a while back. I didn't have much for equipment so I used some rather unconventional methods lol. I don't like posting links on other folks' channels but your welcome to check it out. Thanks for sharing, Keith!

[@roberthamilton9730]

Perhaps using a hack saw a file. I'm just guessing here!

[@Just1GuyMetalworks]

@@roberthamilton9730 there was definitely some file work, can't be certain about the hacksaw though... maybe 🤣.

[@smoothstoneprojects2431]

Hey Keith thanks for another one. Tell Elliott I said hello.

[@alstonofalltrades3142]

9:27 you had me looking up definition for holidays hehe.

[@alstonofalltrades3142]

@@flat-earther a break from work, also can be a trip somewhere. But I'm a Limey. Anyone know if it's American or regional to a few states?

[@cyrilhudak4568]

I think it's a "Fennerism"

[@alwaysbearded1]

@@alstonofalltrades3142 Holidays is a term used by my shipwright friends for places missed when painting, varnishing. Makes perfect sense the way Keith used the term. I guess the idea is you missed a spot while thinking of a holiday or vacation. Don't know if it is regional or if it came here from elsewhere. I just learned it from the guys I worked with. I've heard it used here since but I'm from the San Francisco Bay Area in California so we get phrases from all over. Now I know a new use for the word.

[@alstonofalltrades3142]

@@alwaysbearded1 ahh nearly always a problem with trips! I was thinking also that the surface was all neat and shiny as wanted, except there was still a few 'breaks' in the surface

[@HNIZAR45]

nice work

[@davidjames1007]

Very interesting, looking forward to the follow on.

[@WreckDiver99]

So...does this mean you got your own 3D Printer now? They are addicting, and I can see you creating lots of patterns now. Clark's going to be busy! LOL

[@dvddale111]

Addictive?

[@WreckDiver99]

@@dvddale111 correct..ADDictive. :)

[@gorillaau]

@@WreckDiver99 Additive??

[@jacksoncroyce6063]

I swear your speaking intro gets faster with each video lol. I love your videos, thankyou for sharing.

[@scorch767]

Awesome!

[@petert3355]

Stupid question time. Would the initial cleanup on the casting have been better off done between centres? The hole appears to be pretty true so working from there, and getting the bit that was in the jaws initially centred I think might have been easier. Or am I completely wrong?

[@MrBhujbalgv]

Great job, eagerly waiting for next vedio..

[@tinker5349]

Hi very interesting video, thanks for sharing.

[@biglakehotrods381]

I could watch this process all day! Great work. Why do some cutting processes need cooling fluid and some not? Thanks for sharing!

[@Ed-nq2rr]

Can't wait for the next step

[@tpobrienjr]

I guess bevel gearmaking is all in the angles.... I applaud the Delrin trial run - good idea.

[@jensschroder8214]

well explained

[@leeklemetti1887]

Hi Keith, off to new dimensions. With worry in your comments, we know there is triumph very near. Keep up the tuning.

[@sydneyshinshi]

Casting worked out fine.

[@mdouglaswray]

Thanks!