Metal Planer Restoration 36: Cutting Spur Gears on a Horizontal Milling Machine with a Dividing Head

[@cavemaneca]

After about 3 years you're getting so close to making chips with this great old machine. I'm always happy to see another video from you.

[@jcopley100]

As if they aren't already good enough, Keith's videos always come with comments that are a master class in machining all by themselves. So many ordinary guys with so much valuable knowledge that they are happy to share with rest of us. Y'all helped build this country I love, and I'm truly grateful.

[@canuckloyalist4681]

Those gears will outlast EVERYONE watching this! Nice work Keith!

[@ROTTK9]

should might be the more appropriate word, as with life stuff happens, they could be dropped or when they are in place and working an object could get between them or something could go wrong and bust a tooth. so in normal use they should last a long time.

[@canuckloyalist4681]

@@ROTTK9 Following those parameters NOTHING will last....let alone cast iron gears.

[@mdouglaswray]

22:04 - Final product = poetry in solid form. So nice. The original teeth look worn, to say the least. 125 years?? Yeah, let's see anything current last that long. Always a pleasure to watch someone doing it right. Thank you.

[@chieft3357]

Spur gear cutting is a very satisfying thing for me to do. I'll try climb cutting like you did the next time I need to cut a gear. Thanks for your videos.

[@peteengard9966]

I can't wait for the bevel gear cutting video. Great content as always.

[@DAKOTANSHELBY]

Love your explanation as to why you had stayed with cast iron! Put your critic in his place. Great video Keith!

[@MaturePatriot]

I bought a Steinel S4 horizontal mill mainly for cutting gears and keyways. Now I need a dividing head. The dreaded purple thumbnail! LOL Thanks for this video.

[@howardhiggins9641]

There is something so satisfying about watching those gear teeth form up.

[@sharkrivermachine]

Now that I have a horizontal mill gear cutting is more plausible. I don't have any gear projects planed yet but they will be coming. Thank you for sharing.

[@cbhirsch]

Planner is getting close!

[@jamesdavis8021]

Always happy to see a new video from your channel

[@Dudleymiddleton]

Keith sure does cut the purtiest teeth! :) Great video, satisfying to watch a traditional manual method of gear cutting.

[@MarkSeve]

Always a thumbs up. Thanks for sharing Keith

[@morgan19811]

Loving the channel binge watching I adore old workshops and or equipment I mean if gear lasted over a hundred years of use and they got broken teeth simply because of a unfamiliarity of construction or seizing in this case you have to be impressed and why change a good thing! If it’s not broke don’t touch it. But if it’s out of square just you watch out come the 🛠.

[@cavemansmancave9025]

Cast iron is a great material for gears. It machines great, it’s a little harder than annealed steel, it will lap itself in, it’s as strong as annealed steel, it’s slightly self-lubricating, and doesn’t ring like steel does. Great choice and great video, Keith. Thanks, John

[@bulletproofpepper2]

Thanks for sharing your vast knowledge. Stay safe and well.

[@josephmagedanz4070]

Looking forward to the beveled gear episode, too. Thanks, Keith!

[@EricMBlog]

Of course, This Old Tony has two great videos explaining the first few minutes of this in detail.

[@tinker5349]

Hi, well done and thanks for sharing your video on those very well made gears

[@MrPatdeeee]

Good show Keith. Thank you for sharing this with us. May Jesus bless you and yours always kind Sir.

[@air54plane]

Good job,now they will last 100 years!

[@porthose2002]

Beautiful job, Keith!

[@timroethle8862]

Thanks for another great video. I sure enjoy watching you make all the cool things that you make. And I enjoy your precision and your desire to do things the right way! Again thanks

[@scottvolage1752]

Getting closer to finishing. Always informative and fun to watch.

[@danielabbey7726]

Great video, Keith! Not much information on KZbin about measuring proper depth with gauge pins, so that part was very useful.

[@elsdp-4560]

THANK YOU...for sharing. Enjoyed.

[@jerrycoleman2610]

Keith, Nice job on the gears for your planer, thanks for sharing your video.!.!.!.

[@garywalters4286]

Keith another great video on gear cutting,please keep up these mid week videos!

[@DevinHeaps]

They turned out very beautiful. Well done. Thank you for sharing.

[@frankewing1769]

I think this is your best produced video ever.

[@KaosSchmoo]

I would love to know what camera/lighting he uses, it's very high res and nice and bright.

[@pnwRC.]

I always enjoy watching you make complex parts like gears!

[@neila2953]

Always good when you get round the gear and have a full tooth at the end. Nice job Keith

[@Just1GuyMetalworks]

Great job! Gears are so much fun to make 😊. I've only ever made a couple but so satisfying 😁. Thanks for sharing! Cheers!

[@propulsar]

Great video Keith. I was really interested to see how that dividing head works.I had no idea how gears were made and now I know.

[@nevetslleksah]

Nice job. Thanks for making the video. A couple weeks ago, I cut a couple change gears for a FB users South Bend 9” lathe, 18 DP, 26 and 28 teeth. Satisfying work. Stay healthy.

[@staciedziedzic8706]

Hi it’s Stacie! I absolutely love watching gear teeth get made! They turned out so awesome! I also love the fact that the machine was in good shape! Just love this video!

[@tiredoldmechanic1791]

I recall being taught to make two cuts 180 degrees apart on even tooth gears or three cuts on odd tooth gears, measure those and cut deeper if necessary. Once the cutting depth is correct, make the remaining cuts.

[@howardosborne8647]

Yes,I've used the two opposing teeth and then measure with gauge pins method to establish final cut depth. It works well.

[@tomnugent845]

A great, detailed explanation of cutting gears. One more step in the rebuild

[@edsmachine93]

Great content Keith. Nice work, I agree with your decision to use cast iron. This will last for many years with proper use and maintenance. Thanks again, Ed M.

[@paulcopeland9035]

Especially, Dura-Bar. It is a premium ductile product!

[@Cromwell648]

Nice job Keith, and you're quite correct. Cast iron is a good material to use, 125 years, proves it.

[@stumccabe]

Thank Keith. I must admit I wondered why you'd chosen to use cast iron instead of steel - your explanation convinced me you were right!

[@eliduttman315]

The "malleable" iron Keith cut the new gears on is less brittle than the OEM "gray" iron. Come back in 150 years and the replacement gears will be going strong. ;>)

[@mcgam2000]

Great video of making gears in a horizontal mill that is what I have so appreciate it

[@mdouglaswray]

18:55 - crystal clear reading. Poifect.

[@billrichardson4873]

Thanks Keith, I learn so much from you guys in the Ytube machine shops!!!!

[@WeTrudgeOn]

Seeing a blank being turned into a productive member of society is always cool, especially when it comes to gears being formed.

[@mdouglaswray]

Perfect camera angles on the measuring. Slightly closer and steadier on the mic barrel would be lovely. It's been eons since I've used mine. Bet you've got a video on using one.

[@altonwhipkey2411]

Another great job, Keith

[@TheAyrCaveShop]

Nice job Keith, That first 10x looked you had converted the old girl to CNC. Good tips and info...

[@avoirdupois1]

Great to see this process, and I enjoy hearing your comments about the materials.

[@bcbloc02]

Cast iron sure does machine nice!

[@trieutran2114]

You are a teacher, you are máter, metal player .

[@BarnyardEngineering]

The cast iron teeth will also break before something else down the line that's much more complicated to fabricate, breaks. It's a level of protection, though probably not intended in the original design. You hope a belt slips first, or if there's a shear bolt/key, but if it gets this far it will get no further.

[@robertoswalt319]

This is the exact thing I was thinking of. A sheer bolt in the proper place can save a gear box.

[@stuartdixon9552]

Cast iron is a wonderfully forgiving material that is often overlooked by many engineers. I use extruded cast iron for bearings instead of bronze. Having free graphite the cast iron has exceptional wearing qualities. Thank you and good luck with the planer restoration. Stuart Dixon.

[@azuritet3]

And if they break again then he can just make more.

[@mdouglaswray]

Yes, no doubt machines of that nature can be misused (excessive cutting depth, wrong speed, etc). The problems taking it apart certainly added to the issue. I think remaking them was a fantastic tribute to a very useful tool. Those parts had paid the price. Wonder how many parts THEY made BEFORE they busted. Lots. :-D Cast iron, shmast iron.

[@HiltownJoe]

This kind of foresight is what seperates good engineers form excelent engineers. Putting effort into making sure that your product is breaking in a way that is easily repairable is a thing that is very much missing in todays engineering.

[@ramsay19481]

Like the wrench you have on the lock of your dividing head.. Going to have to dig through my square wrenches and see if I have one to fit my model H dividing head... Cheers; Mike in Louisiana

[@jryer1]

Very nice. Thanks!

[@vincentshelpfulhints4085]

just found your channel , thanks for sharing

[@boltonky]

Always great videos the amount of times i needed a gear and given up...if only machining time was cheap and/or more people shared there equipment/knowledge.

[@joeestes8114]

Great video! Thanks for sharing!:)

[@karlhrdylicka]

Excellent job as always Keith. just goes to prove you don't need 50 yrs experience as a 'tool' maker to get good results , pleased in a way it's a 2 part video on these gears as the first one opened up a can of worms with comments and advice, one being far to critical on the way you do things in your own workshop.

[@thonnogeengineering7745]

Haha, just looking through the comments to see if I could find him complaining about something else

[@karlhrdylicka]

@@thonnogeengineering7745 Now I have been made aware of the troll I have seen he/she/it, on other KZbinrs channels , and has now started trolling me when I leave a comment, I wasn't aware that I had such a magnetic personality .

[@jerrywallen8327]

Thanks for sharing you’re a very talented machinist!

[@carloscordero4204]

Wow that was easier then i though ! good process i bet it took a long time too figure out then to make! Nice always a goos job thanks Keith!👍

[@naillias]

Great detail in videos!

[@fishermanyt8187]

Lovely gears, remaking using the original materials on these beautiful old machines just feels right. Yes there may be better materials but this is the way they were made. This is 100+ years old and still going how many machines with modern materials are still going let alone worth a rebuild

[@kenny5174]

Good video, also great camera control..,.

[@tpobrienjr]

An involute gear's shape is a pretty sight. I had never seen one actually made. Thank you! 125 years is pretty good, IMHO. I don't think I personally will last that long. 76 and counting.

[@dumbo800]

Remember, this is an approximation of the involute tooth. To get a true involute tooth it needs to be either hobbed or shaped on a gear shaper. Search in KZbin for 'gear hobbing', as there are some quite decent videos of the process.

[@garywills5682]

Great job Keith. Ok its me and tiny bit ocd i see the hold down bolts and weak washers holding dividing head and foot stock. On that size bolt wouldn't 1/4" thick washers be better to use. Even non hardened steel be ok. I dont know why i automatically see things like that. I probably would have just put a couple on myself but mishapened like that hollars at me. Not critical i know . I do love gear cutting n spiral helical gears . Its a world of its own and needed so much. I need to make a few 10 pitch 14 1/2 degree 32 tooth for the table and head raising gearboxes of my 20inch rockwell delta drill press with power feed. Not sure ill be able to since my spine pain put me in bed to stay it seems. What a press to own n restore beautiful to me. Thanks for your videos they help to fill my void.

[@biggreasies537]

Yes, I agree with you on the T bolt and washer combo to hold down vices and dividing heads, using thin hardware store washers that bend and wallow out the surfaces that they seat on is not a workman like thing to do.

[@mdouglaswray]

Note - on prev comment, mic reading is perfectly legible. Just not razor sharp like the rest of the video. Outstanding production quality as always.

[@ronsmith3065]

You have more patients thany anyone I know. Or have ever heard of.

[@honorharrington4546]

Better to have an easy to replace part break than an expensive one.

[@boldford]

Another advantage CI gears have over steel is the self-lubricating properties because of the free carbon.

[@carloscordero4204]

That Is A good job

[@EricMBlog]

Does the handbook include the pin measurement for odd vs even gears? Because on a odd tooth gear, you would be measuring at an angle across the gear, not straight across.

[@radiohirsch]

Wondered the same thing...

[@lianlim9119]

Good gears

[@kimber1958]

Very nice

[@ErikBongers]

The math on the dividing head: a full circle = 40 full turns on the dial. So, each turn gives you 1/40th of a circle. The plate has 19 pins, each pin thus further dividing everything into 19 parts. So 1 pin forward means a division by 40*19 or 1/760 of a full circle. A full circle is thus 760 pins forward. We want 19 divisions, so if we progress 40 pins, after 19 times 40 pins we are at 760 pins = full circle. 40 pins on the 19-pin plate = full turn + full turn + 2 pins, or 19 + 19 + 2.

[@howardosborne8647]

The plate holes are a fractional division of the primary ratio. I must admit I cheat on this process and just use a quick reference table I have that covers all my dividing plates and what divisions are achievable. Lazy but quick and convenient.

[@elischultes6587]

I just realized I was no longer getting American Rotary adds in front of all YT videos. I’ve watched a few of Keith’s videos again recently. I wonder if I’m going to get 3 phase inverter adds again.

[@homeryoung7436]

Morning Keith

[@guillermogutierrez5736]

Hi Keith, nice work. Could you show us (your method) how to align the cutter in the center of the workpiece? I'm wondering how to do it. Best regards!

[@BlownF150]

Need to invest in a thermal imaging camera, would love to see how heat builds up during milling and grinding operations. You and Abom need FliR sponsorship.

[@MikeT]

Cool, very informative

[@tnekkc]

I love the "I broke those teeth." defense.

[@davidkassover9832]

I've learned much by watching your videos, Keith, thank you. My dividing head didn't come with that doohickey (scepter?) that marks the necessary holes beyond full turns. I'm tired of off by one errors; how can I add one to an existing head? Thanks much.

[@gd2329j]

A cast iron gear can be a good thing ! Like the soft pin coupling in sum lead screws . With all that kinetic energy flying around if it all locks up you just brake a gear or pin with the lead screw .

[@chrisretusn]

All geared up now.

[@Jeremyurffer]

Great job good video.

[@erinschlameus3628]

There is another benefit cast-iron. If you are using steel gears & something goes wrong something more expensive than just a simple gear is going to break! With a cast-iron gear you just have to replace 1 little gear.

[@alt-w7130]

Great project thanks, enjoy your detail information and procedures on the spur gear making. Do you make helical gears?

[@CezaryAkakios]

What's the plan for deburring those gears? Quick hand file? Leave it be? Vibratory tumbler?

[@williamsquires3070]

And don’t forget reason #3: cast iron is easy to machine and doesn’t require cutting oil/lubricant! 😎

[@danandyong6653]

Don't forget also people, cast iron gears act as a "safety" as well. If the machine has a crash the inexpensive cast teeth/gears will fail versus An important or expensive part of the machine, like a shaft for instance. If steel teeth have no give, something's gotta give! If used properly, the cast gears will last the life of the machine

[@tomp538]

I'm surprised you didn't do a braze repair on the gears. But, your machine your decision as to the how to...

[@chrisjohnson4165]

Not all cast iron is the same, and some forms (SG) have graphite content, making them very strong. Also, most cast irons form a fantastic hard skin, which is perfect for gear teeth.

[@WilliamTMusil]

Hiya Keith

[@brynjones4579]

Great videos, I'm learning so much. How did you make the notch in the shafts, I don't believe you made them in the last video?

[@paulcopeland9035]

Broaching. Use the "G" word and look it up.

[@brynjones4579]

@@paulcopeland9035 Many thanks

[@user990077]

12:10 If there is an odd number of teeth how do you place the gauge pins directly across from each other?

[@marcusmerrin192]

I had the same question. I suppose that if you do the trigonometry, the error of 1/19 of a circle makes a negligible difference in the diameter measurement. If it was a gear with much fewer teeth I suppose it could be a problem.

[@dumbo800]

@@marcusmerrin192 There is trig involved in calculating odd tooth measurements over wires.

[@howardosborne8647]

These cannot be odd numbers of teeth as they are 2:1 ratio valve timing gears so only even number 2:1 gears will do for this purpose. As someone below points out a trig calculation and 3 pins can be used to measure odd numbers of gear teeth.

[@phildcrow]

The Moment of Truth: when you cut that last tooth and it's symmetric to the ones on the left and the right.

[@garymucher9590]

Always interesting cutting gears. Have you ever cut helix gears? I would be interested seeing that type setup.

[@warrenwise8127]

I believe its called a differential dividing head?

[@dumbo800]

You need to have a perfect involute tooth form for helicals. You need to use a hobber. If it is a differential-equipped hobber, you set your indexing gears normally and then do the infuriating math to find your differential gears for how much you want the work table to index additionally. I say infuriatingly because you do not get exact gears to work with, but rather you need to do trial and error until your math works out to at least 5 and preferably 6 decimal places for a gear combo.

[@Landrew0]

I wish this had been a one part video.

[@matthewq4b]

When we gonna see the vertical head for the Kearney & Trecker get repaired.....still waiting and looking forward to that.

[@HiltownJoe]

Dividing Heads are one of my favourite kind of engineering p*rn.