Metal Planer Restoration 35: Cutting new Gear Blanks on the Metal Lathe

[@elsdp-4560]

THANK YOU...for sharing. Right on the money.

[@SciPunk215]

The small projects that add up to the big project are the best.

[@assessor1276]

Very nicely done Keith. While preparing these blanks was a relatively simple task, your clear explanations of what you were doing and why plus the fine video work are both appreciated. I’m really looking forward to seeing the gear cutting operation!

[@rodhenry4862]

Nothing better on an early Saturday morning than drinking coffee and watching you machine something! The next video should be even better. Thank you Keith for these great videos! Another step closer to making chips on that machine!! 👍👍👍👍

[@lindsaysmith7014]

My Friday lunchtime viewing! Hello from Arbroath Scotland

[@WeTrudgeOn]

This is why this is one of my favorite channels, just get right to the work at hand, not just talking the project to death saying the same thing over and over for half the video.

[@garywalters4286]

I love your high quality videos,you Adam and Mr. Pete post the very best!

[@ron827]

I was all geared up to see how Keith does this.

[@firearmsstudent]

Can't wait to see him cut his teeth on this.

[@Hoaxer51]

I couldn’t wait for the dad jokes! Thanks guys!

[@iamthetarget52]

I see what you both did there. It meshes nicely with the video.

[@gav2759]

Everyone's entitled to their own pinion

[@kurtarmbrust]

The dad jokes keep piling on! This thread has got some teeth to it.

[@1ocean515]

Love the process. Looking forward to watching you cut the teeth in.

[@carloscordero4204]

So nice too make what you need ! That's a quick video would have been nice to see the teeth made! Nice too see the Planer coming along! Thanks !!

[@greavous93]

If you watch the ending again he says the teeth are another episode. Dont go through life looking for something to complain about.

[@grntitan1]

@@greavous93 Well said.....!!

[@harpomarx7777]

Always a pleasure to watch your work.

[@rickpalechuk4411]

Really taking shape Keith, thanks for sharing, Cheers

[@denniss5512]

Hi Keith, Well I just inherited a 13" Leblond lathe and automatically refered to your restoration from 2016. Seems like yesterday. Thanks for being so down to earth and reasonable on these projects! I have to make a new cross slide screw and nut, but you made videos for that as well!

[@scottvolage1752]

Keep up the good work Keith. Like everyone else can't wait for the next videos.

[@KG-yn9qi]

Thanks Keith! I like the lathe work. Enjoy the restoration of machinery. Started watching while you your rebuilding the plainer/ matcher.

[@richardcurtis556]

All the work you put into that Monarch lathe really shows in it's performance. I'm really looking forward to seeing you cut the bevel gear.

[@eXactModellbau]

All the work he put into that lathe, and then he let fly the cast iron dust all over it. ☹

[@jtthill5475]

When you first put in the Durabar I was thinking you have to bore out the center anyway, 'why not put in a center to start with and have the extra support?' Turned out you needed the center. Nice work on making the blanks, fast and easy. Thanks for sharing.

[@mickestahl6178]

Love your super nice work as always.

[@SuperAWaC]

i miss getting to work on parts where the tolerances are "as long as it works". so relaxing.

[@tpobrienjr]

I noticed the calibrated hand checking the diameter of the bar. Keith, you have the touch.

[@joopterwijn]

Keith, it mite sound kind of lame, but could you show in a video what your steps are in cleaning up the lace after turning. I can guess ( chip removal, brush, cloth, oil etc ) but I think it would be interesting to see what to do to keep a shop need and tidy 😎 probably more work than a lot of viewers realize!

[@richardscott6716]

Hi Keith. The camera work on the lathe was particularly good today. Salut

[@craigtate5930]

I had a step toe shaper a few months back that sheared off a few teeth. Wound up welding material back on with my flux core welder then removed the the excess as needed by eye. Worked well with the tools I had at my disposal at the time. And I think much less time consuming then trying to build it from scratch. However another part (ratchet wheel) lost so many I built it from scratch

[@jimbarchuk]

There we go! That's the way it's supposed to work!

[@MrPatdeeee]

Good Show by a VERY intelligent and kind man. May Jesus continue to bless Keith with talents and kindness.

[@drewmog123456]

I think it was evolution rather than Jesus!

[@سیدخلیلاحمدشاھ]

Great ⚒.

[@rogerbird6151]

Hi Keith, I was all geared up to. Lets get our teeth in this!

[@stefanpariyski3709]

9:26 Being able to see the reflection of the tool in the work piece is pretty cool!

[@willgriffin3490]

Loving these vids! Can you show the cutting for the keyway on the smaller gear?

[@CathyInBlue]

@Keith Rucker Planning on doing any heat treatment/hardening on those eventual teeth to maybe prevent a repeat of the same type of damage in the future?

[@debuchmartin9383]

Hi Keith, First of all I love your videos, they are educational and also a kind of relaxing to me. It helps me in understanding the construction and maintaining the machines in my private wood workshop. My machines date back to the early 1950 (most machines) up to the late 1970. My question may sound stupid to non-mechanic guys, but in some videos you showed how you filled up the metal gap in a gear by brazing and then cut the missing teeth only? Why do you rebuild the complete gear this time? Well it's hard to judge from the video but there the remaining teeth look ok to me. Kind regards, thumbs up and thanks a lot for sharing your skills with us! It is inspiring to me to see you work. Cheers and greetings from Germany (still struggeling with imperial measure units 😂) Martin

[@jeffbeck6501]

This is exciting. The NFL is toast.

[@garthbutton699]

Any time I had to fabricate a piece for my dad he would give me my marching orders by taking pen to a napkin,those were good times.

[@WilliamTMusil]

Hiya Keith

[@ypop417]

Things are Shaping Up Keith LOL

[@ratmadness4858]

2 mins in and I know this is going to be interesting

[@karlhrdylicka]

Rat Madness , What more interesting than the comment section .Wow it is gonna be good ,never watched a Keith upload that wasn't excellent content.

[@haledmondson2756]

Keith; Is the use of cast iron for gears better than using a grade of steel? Wouldn't steel make a stronger gear?...Hal

[@jwaterous224]

Interesting camera angles on this episode. Further away from the work I think. Good to experiment with the shots.

[@talltimberswoodshop7552]

I was staring blankly at the screen.

[@CanizaM]

Why do lathes usually spin counterclockwise? Because drills usually spin clockwise. The close-up of the drilling shows that very clearly.

[@eXactModellbau]

A lathe turns clockwise. You have to watch from the headstock, so as You do at a milling machine or a drill press.

[@earljtharp]

I was wondering how you keep from crashing the tool into the chuck. Is there a stop built in which prevents it or do you just have to be careful?

[@Blazer02LS]

You just need to be careful.

[@Blazer02LS]

Not on many manual machines, and even the ones that have it, you have to set it up for every job and tool holder.

[@Blazer02LS]

Strange that none of the ones I've owned had any type of automatic carriage stop. That includes the 3 south bends up to the 13" and the Monarch 18". You could set a stop on them, but it did nothing to actually disengage anything. It was designed so the operator let it run close, disengaged the feed and went to the stop manually.

[@grntitan1]

@earljtharp Same way you keep from running your vehicle through the garage. You STOP!!!

[@Blazer02LS]

They don't have and never had any type of automatic disengagement on the carriage. There are a LOT of machines out there that are the same way.

[@greggoff4990]

Whoa there brother. Everyone knows sharpum is blue.

[@bobengelhardt856]

I'm surprised that a drill bit was accurate enough for the bore. I expected that a boring tool would be used.

[@petert3355]

As if we needed any more proof of Keith's craftsmanship. The left thumbnail says it all.

[@WayneT51]

Keith, one question. Why cast iron, is that so it would fail rather than do damage in deeper?👍

[@MadDawg91108]

The answer to your question is at 1:46 ... because the original gears were cast iron.

[@tsmartin]

Looks like there could be a bit of parallax error on the dial indicator set up. Maybe it's an optical illusion.

[@MegaLostOne]

Keith do you use a local supplier for your stock metals or do you order online? I'm trying to find a place for ordering thick wall tubing and just curious if you have an online supplier you have been happy with dealing with.

[@MrRedstoner]

If I were to chance a guess he's using Mc Master Carr, given how he mentions it from time to time.

[@afnDavid]

Ouch! Your poor fingers and knuckles

[@robertbamford8266]

Thanks for video! For the extrusion for the first gear (2+”), did you need the tail support because it was flexing?

[@firearmsstudent]

Yes. It may seem innocent, but when you are cranking the hand wheels, you are exerting hundreds, if not thousands of pounds, of force into the material through the tip of the tool. If you're cutting at longer than 3x the diameter, the deflection in the material, depending on the below formulas, is too much for a smooth and accurate cut. (An OD will be oversized and an ID will be undersized) You have to remember that the metal does not want to be cut, so we need to hold it in place as firmly as possible, which means minimizing deflection. This deflection for a piece of stock held only in the chuck, also known as cantilevered, (which was in the first attempt) which enables the end to flex when a force is applied along its length, can be calculated using the formula: deflection=(force applied by cutter×(distance from the chuck to the cutter)^2)×(3×distance from chuck to end of stock-distance from chuck to the cutter)/(6×stiffness of the material×the rigidity of the shape). For a circular bar, the rigidity of the shape, more formally known as the second moment of area (Abbreviated as I in most equations), can be found by the formula (pi×diameter^4)/64. The rigidity of the material, more formally known as the young's modulus of elasticity (Abbreviated as E in most equations), can be found in engineering handbooks derived from experimental data. Eliminating the stock's ability to flex at the end by supporting it from both ends with the chuck and a tailstock center creates a stiffer arrangement with less deflection and yields a formula of: deflection=(force applied by cutter×distance from chuck to cutter×(distance from chuck to end of stock^2-distance from chuck to cutter^2)^1.5)/(9×square root of 3×distance from chuck to end of stock×E×I).

[@emilgabor88]

No. Dont now what the other guy sad. The flexing is in the 3jaw chuck . in 4 jaw independent you could do this easely

[@johncollins2037]

@@firearmsstudent . It may be because a rough cast material in a 3 jaw chuck is not a true diameter, so there is no chance of it holding true over that length. (just guessing). Extended jaws may help, or even soft jaws so they may bite into the imperfections of the stock and even out the loads applied.

[@Blazer02LS]

Most stock isn't very true. There are some items like ground bar and such but most off the shelf stuff falls into the "close enough" category. If it is bad enough you get an interrupted cut, but that is a different problem than what is going on here. The issue here is simply the stick out. Every amount of distance you are away from the support of the chuck introduces some deflection due to the leverage from the cutting tool. Even the chuck itself can deflect on the spindle bearing if you apply enough force. As the deflection adds up you get chatter where the material deflects, then springs back against the cutter and cuts in a somewhat sawtoothed pattern. Add the center and tailstock for support and you go a long way to limiting the problem. However even then you can still deflect the center of the part depending on the material and the depth of cut. That is why follow rests came about. Support right near the tool as is works.

[@jimmurphy6095]

Keith will scrape surfaces to

[@paulcopeland9035]

No, doesn't seem to be.

[@ramanshah7627]

Yup, the latter part of this video made me wince a bit!

[@cannon440]

I think of cast iron as brittle, wouldn't mild steel be better for gear making?

[@Blazer02LS]

Original is cast. Depending on the use cast iron has some advantages over steel.

[@Blazer02LS]

Not really. The reason castings set around a while before machining is for stress relief in the casting. It is also why cast iron gets heat treatment for many applications, that does the same thing. In this case it isn't an issue because this isn't truly cast, it is extruded so the stresses are not an issue.

[@xenonram]

@@Blazer02LS Don't mind Steve, he's a whiner and is always βιτcλιηg about something. He seems to "have done x for 50 years," where x= whatever the conversation is about. He's a bit slow.

[@bcbloc02]

@steve gale If cast is brittle it won't matter how long you let it sit for it will still be brittle.

[@Blazer02LS]

Guess Andrew is correct. Castings are left to set to relieve the stress in the castings, same reason why pro engine builders used to love using engine blocks from taxis and police cars. The constant thermal cycling acted as stress relief. It does nothing at all to the grain structure, there is nothing that will effect that once the iron is cast unless you remelt it.

[@iamthetarget52]

I find it sad that Keith's chicken scratch drawings are better than some of the 1990 era drawings from my company.

[@PhilG999]

Yeah. I've done some freehand things that amazed people. I learned my Drafting with pencil and paper, then went to Vellum and ink. Long before Cad existed. Bet a Boss one time (he was a P.E.) that I could draw a one inch line on a bar napkin (we were having a beer after work). Best boss I ever had BTW. Took out a pen and drew the line. He said: "So how do we verify that?" Took out my company made Zippo tape measure and handed it to him. A free beer!

[@hinz1]

Too much rpm on that cast iron, better go slow with heavy engagement. Otherwise the tools burn up. Well, guessed it, 11:04 ;-D

[@paulcopeland9035]

Go to the head of the friggen class!!

[@craigtreleaven7560]

Hey! You didn't broach the keyway on the smaller one.

[@randallanderson4999]

The broaching will be done after the teeth are cut, that way there is a smooth inner hole to turn for making the teeth.

[@BedsitBob]

Shouldn't the holes have been reamed?

[@stumccabe]

Interesting, thanks. Keith, don't you think using your callipers for scribing, especially on a rotating part, damages the tips? Personally I reserve a cheap Chinese set of callipers for that.

[@Blazer02LS]

Not going to hurt them at all.

[@stumccabe]

Blazer02LS I think you're wrong on that.

[@Blazer02LS]

If scratching through a coat of sharpie is going to damage them then they are junk. All of the ones I have are hardened steel or carbide tipped.

[@stumccabe]

Blazer02LS . I have a set of hardened steel callipers that I used for many years and I can assure you that the corners have become rounded by scribing with them. Maybe it's not important if you're happy to replace them regularly. It's just my preference only to use my cheap callipers for scribing.

[@Blazer02LS]

Mitutoyo 505-738, Starrett 798BX, INSIZE 1110-200A are just a few that have carbide.

[@accuracymark]

You need a dro!

[@premierd8988]

why is it that the both holes are not centered ... but I guess that you'll say it's close enough ...........?

[@paulcopeland9035]

"why is it that the both holes are not centered" ? What??

[@premierd8988]

@@paulcopeland9035 watch the big drill......it,s not drilling in the centre of the part ... I sure can see the od running out ,but that will not bother Keith😉

[@paulcopeland9035]

@@premierd8988 ...The 7/8 bit follows the center drill from the tail stock. You are seeing a tiny bit of run out on the OD of the handle feature on the gear, but the center is dead true. BTW, why do you say Keith will not care? He has a beautiful shop full of precision tools that I have been watching him use for years. He always does fine work. I suggest you unsubscribe from this FREE content and leave the hate somewhere else.

[@premierd8988]

@@paulcopeland9035 Okay mate ... I am an engineer to trade .. so a straight line is a straight line .. and a OD or Bore are true to each other or they are not ... end of story . so unless he re-bores it true with a boring bar the the gear will jump up and down .. causing premature wear on the teeth of the said gear and whatever it is meshed to. You are correct he has a few nice tools , but having the tools does not mean the you turn out''fine'' work every time .ask Keith himself . in fact go back through his videos and check how many times he says that it will be 'good Enough'..as for hate I don't hate anyone . I merely point out what I see to be errors the fact that you don't agree is your problem . not mine .and tells me that you have no (or pretty shit) engineering knowledge .I rest my case ......

[@larrywall1642]

DO YOU EVER USE A CERAMIC CUTTING CHIP

[@xenonram]

Ceramic tools aren't really meant for manual machines.

[@emilgabor88]

@@xenonram in sand cast iron i allways use ceramic on manual lathe . and you cant beet it

[@larrywall1642]

I used ceramic tooling for 22 years. D2 tool steel in a roll cutting lathe.

[@emilgabor88]

@steve gale no. In sand cast iron hss or carbide dont last more them 30 second. Ceramic are rezistent to abrazion whitch the odel cutting tools are not

[@emilgabor88]

@steve gale carbide is from tungsten , ceramic is other marerials depending on the grade ... You can machine whit hss but in last 30 second. Back in the day , they grinde 2h machine 30 minuts . if you remove the surface with the sand mix then last a litle bit more

[@Landrew0]

I wish for more one-part videos. I'm not a fan of being kept in suspense.

[@bobrobert6277]

at 8:05 is it normal the tool move that much when you apply pressure ?

[@tsmartin]

I was wondering if anybody else saw that.

[@bobrobert6277]

@@tsmartin i watched thing a few time seams the back lift off and the front go back, im no machinist but when you mesuring in 1/1000 of inch if something moves like that you can't ...

[@davesalzer3220]

“That’s not unusual in this extruded material”. In Johnny Mathis’ voice.

[@PhilG999]

Tom Jones IIRC...

[@pbooth001]

Why do we call a sketch a chicken scratch drawing it is simply a sketch and it is a fine sketch. Don’t denigrate your work.

[@jimthesoundman8641]

Department of Redundancy Department.

[@eXactModellbau]

He knows nothing about feeds and speeds. ☹ Protect Your machines from cast iron dust!

[@grntitan1]

STFU. I get so damn tired of the armchair machinists. You don’t have to be here.

[@jdmccorful]

Enjoyed watching.