Cutting Helical Gears on the Horizontal Mill 4: Machining a Stub Arbor to hold a Gear Cutter

[@robertlewis2]

I think this is one of the most complicated tooling setups you have ever shown on your channel; very impressive!

[@smaggies]

🙂

[@HaraldFinster]

Deep respect for this: you do a really complex setup and create a video on the process simultaneously. A lot of multi tasking must be involved to do so. Really interesting setup.

[@fredclark4033]

An involved set up to cut the gear, and looking forward to seeing the finished project. We'll done so far Keith.

[@llapmsp]

Can't wait to see the cutting process. Really interesting so far.

[@stuartschaffner9744]

Well done! When this is finished, you will not only have a fancy helical gear, but you will have an important vintage mill all set up for general use on future projects.

[@gregorywells7905]

Hope you'll make a small run of these gears, Keith. As someone involved in old car restoration for over 50 years, I am ceratin you'll have the opportunity to sell a few of these gears in the years to come..

[@shannonstebbens6992]

It's been interesting following your progress on this project. Looking forward to the next video to see the test cuts. This is one for the books, from the pre-casting casting of the blank to the finished product. Quite a journey! I hope we can see a future video of the engine this is made for in action.

[@NeilABliss]

This series has been on of the most complicated, yet interesting series. Looking forward to the end results.

[@greggoff4990]

I’m just in awe of the men who made the machine and attachments.

[@hobbiesrus]

That is quite the setup for one gear! This has been really interesting to watch. Thanks Keith!

[@msheaver]

If it's not too late, I do hope you do video and document the practice run on the plastic blank! I love how you make the time and effort to explain why you do what you do!

[@jimcrichton8028]

Your ability to take a complex procedure and break it down into managable segments so that a novice engineer can understand is commendable. Always enjoy your input.

[@azarellediaz4892]

Keith, this may be the most complicated setup I’ve ever seen and I can’t wait to see it in use. It’s great to see a master take the time to teach us, thank you.

[@infoanorexic]

This is one of those setups where it won't make sense to me until I see it in action. One other procedure I've yet to see is bending pipe in a way that keeps the pipe wall thickness the same as the rest of the pipe throughout the bend. Someone told me about it when I was in my early 20's, and I thought the guy was trying to "pull my leg." I didn't say it, but the man read the doubt I had and assured me that it was possible, and told me where there were examples of the work near us, still in use in old steam heat pipe work. It is/was a technique that, once they knew it, was kept as a highly guarded secret. If everyone knew it, it was less work/money for them ... and woe to the pipe fitter that dared to give the secret away. Their fate was probably worse than death. No telling how many "old school" tricks went undocumented, never passed on, because of that greed...

[@thomasconetsco361]

I take my hat off to ya. That was one crazy set up. The plastic test pieces is a good idea.👍🏻

[@PhilRable]

Keith, like your practice run. When I was an apprentice a very, very long time ago my teacher stressed in our young guys 🎉the “6P-principle”: Prior Practice Prevents Pi## Poor Performance”. Love your videos.

[@kevinreardon2558]

Amazing that this technology has become available to folks that can tell the rest of us how it worked. Today, this would all be proprietary information and would not be shown to us common folks. Thanks.

[@Scodiddly]

“Rinse and repeat” - I always appreciate a shampoo reference from somebody who has the same haircut as me.

[@jtrent3960]

Keith is the best on YT for manual threading hand down

[@maggs131]

🎶the best part of waking up is Keith Rucker in your cup🎶 ☕😀👍

[@andywithers592]

Likewise with a lunchtime coffee here in Switzerland.

[@LanceMcGrew]

25:10 was just thinking - man I'd want to practice on something like an aluminum blank before doing the final. This setup brings back memories from many years ago I machined some variable pitch plastic screws to feed plastic bottles into a filling machine.

[@jorgeconcheyro]

The most complex calculation was about setting a proper ratio on the gears connecting the table and the head so that when the blank turned a whole turn, the table moved a precise length. We used to call it a revolution. That was my job at tech school... :D

[@asharahmadarrauf]

Amazing work as always , i like how you go slow and detailed like a proper education channel spoon feeding us kids like a proffesor .. 😀😀🙏🙏

[@noberet]

Every day is arbor day on Keith's channel!

[@waynephillips2777]

Can't wait to see you cutting plastic!

[@geargnasher9822]

The mind boggles. Thanks for taking us along for the ride.

[@ianmorris1675]

Just getting that cutter directly over the center of the gear blank axis is going to be interesting to watch and get right.

[@walterplummer3808]

Great video. I was wondering about a practise piece. Thanks again.

[@kimber1958]

LOOKS GREAT KEITH

[@gonecoastal4]

Keith, King of the cliffhanger, Rucker. Haha. Love the content. Looking forward to seeing how it turns out.

[@rexmyers991]

Oh my gosh! What a set-up. A plastic practice gear is a good common sense next step. I’ll be watching for your next video.

[@TheAyrCaveShop]

Almost there Keith ! A lot of work getting everything setup.. Absolutely with you on running a few test pieces. See you next episode... Thanks...Dean

[@robjchristopher]

Super interesting to see you get to this stage - really looking forward to the test run and the finished product!

[@geraldharkness8830]

your keeping our attention here keith! just cannot wait to see you cutting on the plastic blank/thank yo so much!

[@catfishgray3696]

KEITH, LOOKS GOOD I'M READY, GREAT VIDEO...SEE YOU WHEN...

[@ccrider5398]

Hopefully you'll video some of the practice? I enjoy seeing plastics machined.

[@johnmorris3744]

I was an unappreciative little burrhand/cnc operator many years ago. I’ll be honest, at the time it bored me to tears, but now that I’m older and (comparatively) wiser I can draw on what I learned and appreciate things like this and the fantastic amount of work and dedication that goes into them.

[@thewarlordscalling6537]

Thanks Keith.

[@jasonh3109]

What an awesome machine!!!! Thanks for the video Keith. 👍🏾👍🏾👍🏾

[@chuckmayerchak3071]

Look forward to all your videos. This series has been especially interesting for sure. This setup brings new meaning to the words "mill set up" You should set a vise up on that table for good measure.

[@jameskaufmann7424]

You and your machines are amazing!

[@timmienorrie]

Loving every episode of this series.

[@melshea2276]

Good Morning!😊

[@buckburton7318]

I have watched a lot of your videos over a period of several years, so far this just might be # 1. Good job, I will anxiously await the next segment.

[@nobuckle40]

This has been so cool to see. I've learned a lot. Thank you Keith.

[@CHICOB4261]

I’m starting to feel like the “ball in the proverbial weeds” Keith you make this sound like any guy could do this as easy as changing a light bulb.

[@geneard639]

Welcome to the next level! You have selected, 'Expert Level'. ...I can't wait for the next exciting episode!

[@MrChevelle83]

you knew better than to break tradition without facing first!! LOL fine work Keith, and what an awesome setup to cut that gear!!

[@johnleake708]

thanks for sharing with us I know it takes alot of time to film and narrate the video.

[@phlodel]

I am really looking forward to seeing this setup work.

[@bulletproofpepper2]

Thanks for sharing.

[@CraigLYoung]

Thanks for sharing 👍

[@madjack3314]

Looks like you got it. Thanks

[@thaumaturgicresearchcounci4180]

Really enjoying this video series Keith, thanks!

[@Paul-FrancisB]

Good morning everyone, time for a coffee ☕

[@markmonroe7330]

Excellent video. Many thanks,

[@chadgdry3938]

that is an amazing tool. Thanks for showing it to us

[@jimmymac15]

Great presentation

[@mrfarmall-vk4gw]

Can't wait to see this all in action, nice job👍

[@wrstew1272]

Hopefully the “ client “ isn’t paying setup time for the gear, cause it would be quite expensive! Now you know that I am kidding, eh? The series of what you went through in order to cut a practice has been quite informative. Most of what you record is off the beaten path, old school how to figure out teaching, for which I really appreciate. Can’t wait to see the finished gear. You could show it installed and meshing correctly in a follow up provided the end user is half the quality of mechanic as you are a machinist!

[@Boyracer73]

This is relevant to my interests 😊

[@williamdavis7094]

thank you I really appreciate it

[@afnDavid]

Please stay tuned to the channel for an exciting future episode!

[@randyjones9188]

Keith, when I make stub shaft arbors I put in a woodruff key instead of a short key they stay in place better..

[@johnhiggins9838]

Great video & results!

[@joewhitney4097]

Wow Keith, this makes my head spin but very interesting. Thanks for sharing.

[@YZoxK52m]

Once this gear is done it would be fun to see it installed and maybe running in the antique car

[@ericpaul4575]

14:40 Wow, there is a lot of chatter on the threads that were cut. I wonder if there is excess play in the spindle bearings on the lathe.

[@aserta]

24:11 An achievement picture. Lots of work had to be done to reach this, parts hunting, parts making. Great moment.

[@kentuckytrapper780]

Great video Keith, keep'um coming..

[@natwooding9394]

Now that you are (hopefully) set up to do operations like this, it will be interesting to see how many more similar projects come to your door.

[@garymucher4082]

No better words than making a dummy gear black and practice. If you are anything like me, I'd make a few practice plastic gear blanks. But that is the common sense idea to do first... Thumbs Up!

[@fredcreer1929]

What no chips!. That’s a mental anguish claim, right there. After all that a practice is the only way to go. Great work.

[@floridaflywheelersantiquee7578]

Thanks for sharing interesting

[@railfan439]

Tune in again for the next thrilling episode of, AS THE GEAR TURNS. Sounds like a Saturday morning children's show. Remember Big John and Sparky? Commander Cody and Cadet Happy? Now we have Keith Rucker and Kerney Trecker to keep us kiddies entertained. Thanks for the video. See you at the Bar-Z. Jon

[@marcelpost4052]

At 02:52 it looks like the drill wanders a bit before it cuts the hole. I've seen this before but this is a good shot and shows it clearly. I don't think it's the drill that is moving around. I was under the impression that the tail stock and drill chuck would be very rigid, but it appears not to be. Is this just the age of the machine or did something not get tightened enough?

[@TheJohndeere466]

This is usually caused by the tailstock being adjusted a little off center. On a lathe that is worn, you have to adjust the tailstock side to side to get it cut straight while turning between centers but when you try to center drill up closer to the chuck, this is what happens. Also on most older lathes, the bottom of the tailstock is worn off slightly and this makes the center drill too low compared to the center of the spindle.

[@marcelpost4052]

@@TheJohndeere466 Ah, so it wasn't my imagination, haha.. Thanks for the explanation! :-)

[@SgtCude59]

Another great video . I never got to use the gear box on the end of table place I worked at didn’t have it 😢 I’m excited to see all this working together keep up the good work.

[@elsdp-4560]

Thank you for sharing. Enjoyed👍👀

[@Dudleymiddleton]

Yes - very wise to do a dummy run with plastic. Tom Lipton has a video called "dogmeat helical milling" where he uses a stepper motor to do the lead attachment bit - a bit higher tech alternative I suppose - but nothing beats the old school way!

[@SciPunk215]

When it's all together like this, this setup looks beautiful. The geometry is no longer only in your mind, you can actually see it. So my one question is, why not a Woodruff Key to drive the cutter?

[@johnfriend240]

Eye opener for guys that think gears are too expensive! Don't forget the gear keyway orientation to the gear teeth, as the camshaft to key orientation is already established.

[@JasDarc]

So much manufacturing tech is now computer driven, great to see a man and machine approach is still viable. There may well come a time in the not-so-distant future when these dying skills are needed by humankind.

[@adrianstephens56]

Nice work. Love the precision the DRO gives. I notice the threads appeared to have chatter in them. Does this matter? In fact, could it be a good thing?

[@ianbutler1983]

I have cut threads on a lathe and watched it dozens of times, but it still fascinates me.

[@peterhobson3262]

I love how the spiral comes off of the cut.

[@scottvolage1752]

Good Morning Folks.

[@metrovick5417]

Really enjoying this, always wondered how gears are done. One thing: How do you centre the cutter on the work?

[@ellieprice363]

That’s what I’ve been wondering. The cutter and gear are at 45 degrees with each so it will be interesting to see how that’s done.

[@phillipyannone3195]

Almost there…😊

[@98grand5point9]

Very interesting content. I'm confused though. Won't the teeth be curved? I've only seen these types of gears cut with a fly cutter in other videos.

[@Orxenhorf]

22:23 - What does it have to keep the washer from wearing the back of the head or wearing through itself?

[@Hoaxer51]

One time use should be ok but it would be a good place to put a thrust washer if you were going to run a few of these gears off.

[@Orxenhorf]

@@Hoaxer51 Even though this setup might be one time, any other tooling will have a drawbar with nut/washer potentially causing wear too.

[@Hoaxer51]

@@Orxenhorf, Yea, I was thinking about that, if Keith would not put the washer on, wouldn’t the nut just ride against the shaft that’s turning. Like a drawbar on a vertically mill?

[@larrycleeton]

I really appreciate the complicated setup and adapters needed for doing this old school. Seems appropriate for a restoration part. What kind of modern machine could knock this out easily? A 4 axis mill?

[@TheJohndeere466]

Gear hobber, 20 minute job. This is my barber colman #12 gear hobber kzbin.info/www/bejne/mmTJd6FogdiGZtU

[@WilliamTMusil]

Hiya Keith

[@ProfessorMAG]

Back in the day, would it have made more sense to have a dedicated mill setup like yours (with all the attachments) or invest in a gear hobbing machine?

[@jimhunt5259]

Keith I think your just teasing your never going to cut that gear!! hahaha ; - )

[@ydonl]

Testing is good.

[@roderickjenkins3465]

Fascinating stuff. Have you got a trick for lining up the cutter with the centre of the gear blank? That was my problem when I had a go at helical gears.

[@ProfessorMAG]

You could always make a mark on the gear and then raise the table under the spinning cutter to nick that point. Back off then set your height and let'er rip...

[@MHolt3573]

Was that a Snap On wrench I seen. I thought you was old school Craftsman tool guy.

[@RobertKohut]

It's a process...🙂Interesting stuff... :-)

[@MikeBaxterABC]

Keith and experts on site .. how much would this gear cost of customer ordered|? and delivery time? .. just for the curious|:)

[@donaldshort5789]

I’m sure you got it worked out but you can’t move the x-axis so are you just gonna plunge? I just don’t see how that’s gonna work. Looking forward to your next video.

[@TheJohndeere466]

He will most definitely be traveling in the x axis as he is cutting the gear. Moving the x axis is the only thing that causes the gear to rotate slightly as he cuts it. The dividing head is being driven by the gear box on the right end of the table and it is driven by a gear that is mounted to the end of the x axis lead screw.

[@TheJohndeere466]

I make timing gears for pulling tractors. Im not sure about yours but most timing gears are made from steel such as 8620 and carburized to a hardness of around 58 to 60 Rc. I dont think cast iron gears will last long at engine speeds.

[@NullHand]

Timing gears are typically made with one gear (usually the smaller diameter) notably harder than the other. Cast Iron on cast iron is the most common exception to this. To reduce noise on passenger timing gears, many manufactures have even run steel crank gears against phenolic cam gears. Both the Ford 300ci big six and the GM iron duke in all those postal service delivery LLVs used this while lasting stupid high mileage figures.

[@TheJohndeere466]

@@NullHand I've machined many stock cam gears from yanmars to John Deere to make them adjustable and they have all been case hardened and harder than the hinges of hell. I had to use ceramic tooling to cut them

[@NullHand]

@@TheJohndeere466 I believe it. Noise reduction is not a high priority on tractors, so singing/roaring timing gears probably never entered as a design constraint. Gears made of cast iron are now mostly the nodular iron form, not grey. And also heat treatable. I think the auto mfgs liked them due to not having to surface grind the teeth after heat treating. Power train gears in diffs and transmissions remain surface hardened steel for the shock loads they endure.