Broken Gear Repair: Brazing Up and Machining New Teeth
2016 ж. 25 Ақп.
1 278 815 Рет қаралды
In this second part of the series, I will braze up the broken teeth sections and cut new gear teeth on the horizontal milling machine using a dividing head.
In this second part of the series, I will braze up the broken teeth sections and cut new gear teeth on the horizontal milling machine using a dividing head.
I love it when someone shows old school skills because it's complex, it works, and is amazing to watch and learn! Thanks man!
Hi Keith,I'm a 69 yr old woodworker and have been watching your channel and Adam Booth's channel for several months. I find the work you guys do fascinating to say the least. I just purchased a mini lathe to try my hand at machining. I believe that you are never too old to learn something new. You are truly inspiring. Thanks for the great videos and the time you dedicate to demonstrating these wonderful skills.
+Tom I Good luck with your new lathe! I think that you will find the work very satisfying. Like anything else, just get out there and practice and it becomes easier and easier!
+Tom I Good luck with your new lathe! I think that you will find the work very satisfying. Like anything else, just get out there and practice and it becomes easier and easier!
I had to have this type of repair done several years ago, and was charged what I thought was a very fair price. If I had seen this video first I'd have happily paid double what the machinist charged me! The time, machinery and just good old fashioned skills it took are outstanding. Thanks for sharing.
What kind of machine did the gear come out of it I may ask?
@@2jpu524 A marine gearbox from a small yacht. Never had any further trouble with it.
I must say i have never seen anyone fix broken teeth on a cast iron gear before. I would have thought it would have fractured and fallen out after the first couple passes. Learn something new everyday. Thanks for the useful information Keith and for the great videos. Two thumbs up
+Larry De Silva This is a trick that has been used by many people over the years and it works pretty well.
Another great video on Gear Cutting, I never get tired of watching this process Keith. Thank you mate.
I didn't know gears can be repaired. By watching this video, it was extremely fascinating! I enjoy seeing vintage American machinery at work. Well cared for. Thank you Keith!
+Kurdt M Thank you for watching!
I love this video, Mr. Rucker really go through the whole setup at a perfect pace. Didn’t rush through anything. It reminds me of my first day at the machine shop class back in the 70’s where the teacher really spend the time to teach you right the first time. Mr. Rucker also has a very pleasant voice which is very good for a new student to listen to and if any school has him as a teacher, they should be super proud. Thanks for making this video sir.
Years ago I had to do a similar thing. A couple of different things: preheated the cast gear thoroughly and stood it up in sand, when it was filled the gear was completely covered in sand and left (I think it was left until the next day), also the filler was keyholed, which made for a very secure root for the teeth. Last I heard of the machine it was fitted to, it was still running fine after over ten years. Great to watch, thanks
Just like to say thank you Keith for your clear explanation of what you were doing and why? As a retired engineer and machinist I've repaired a number of cast iron gears with broken teeth this way using Sif-Bronze rods and all of them have been fine. The back gear on my South Bend lathe that I repaired with Sif-Bronze rods about 55 years ago is still working well despite having had a lot of heavy use.
Holy smokes, I really like this machine. When he extended the arbor support shafts I was impressed. I been around many machine shops but this one is a first for me. Really cool.
Kieth, as usual another great video. Thank you for your time spent putting these together.
+norm hays Thanks for watching!
Excellent my friend! Get vid for a Friday!! :-D Thank you, as always buddy! Hopefully the builders were able to get in and get some work done on the shop this weekend for ya!
+Brian Streufert Unfortunately, nothing got done on the shop this week. They have been waiting on the metal roofing to come in - it was due in last week but did not get here until Today (Friday). They say they will be here on Monday morning to start back....
Some fifty years ago, I was completing my apprenticeship on the electrical side of things. Where I worked held a fairly comprehensive machine shop, and one of the items was the indexing machine which I never found the time to watch or learn it's function. Some fifty years later, all is revealed. Thanks for the time!
This was so informative. I love watching a machinist work on fixing broken gear. It allows me to see what my dad would of done when he worked at Grant Gear during WWII or at H.K. Porter in the 1960s both were in Boston!
Ohhh, Keith, feels so good, to hear the intro sound of Your work vids again.. Good success, and THX, even my 83 year old father learned a lot.. Greetz,
+Markus Lineal (LinPoTec) Thank you!
Man, watching you work those old school milling machines never gets old! Wish I had access to a shop like yours!
Thanks Jason!
Reminds me a little bit of woodshop class back in high school. We had a ton of old band saws, lathes, and drill presses that dated from the 1950s - 60s. But the planers, routers and table saws were much newer.
Me to and some one ego testched me to us em 😁👍
Keith, you are a great down-home guy that is always a pleasure to watch and listen to.
Skipped through this for quick review. Enjoyed it the first time I watched the series start to finish. Always nice to see the completed part.
Zen and the art of cast iron gear repair.
Great job ! Wow ! Seeing how passionate you are and all the tools you have, I wish I could fly to your place and learn from you.
I watched my grandpa brazing teeth on a caterpillar bulldozer driveshaft back in the 1960's and removing the excess with his lathe and cutting new teeth with his milling machine very similar to your method. Brought back a lot of memories of true craftsmanship and skill. Thanks for sharing!
My grandpa was a machinist and growing up i used to watch him do repairs like this on old farm equipment all the time
I helped my grandfather repair a farm combine transmission gear one late night in the shop - it must have been 40 years ago. several teeth are damaged/missing. An arc welder, oxy/acc torch, bits of tool steel, lathe, angle grinder, and metal files - were the tools we used. As well as a couple pots of coffee. The repair lasted at least 3 days - when the expedited parts arrived from Chicago. As I remember the repair was time critical as we need to get the harvest done before the rains hit.
My father taught me how to braze. To do it right proper techniques need to be followed. I have repaired several gears with similar techniques. That was nearly a half century ago.
Started my apprenticeship as fitter and turner then into toolmaking. This brings back fond memories of our training and the equipment used. ‘‘Twas many years ago, but still embedded in my mind. Great pastime and interesting video series. Well done.
Masterclass - not just in the execution, but also the presentation.
I am 61 and still doing auto body repair. I love watching your videos. please keep doing the vids.
4 years , better late than never, Keith Sir engineering Maestro thank you, loved this vid !
Really enjoyed Keith!! From one who has never done gear cutting, I learned much. Thanks, Bob
+Bick1027 DE My pleasure Bob!
Hi it’s stacie! Awesome job Keith! I love watching stuff like this! The teeth turned out really well and I love the humor too! Thanks for a great video!
That K and T really gets her done nicely every time - Thanks for sharing the particulars.
+John Strange Thanks John - I just love that old machine more and more!
Machinery that was built to last old school engineering nostalgic but still cranking out quality products thanks for sharing your skills...
Really enjoy your channel Keith. I am 12 years from retirement, hope to be spending my time doing things like this down the road.
lovely, great job, never thought it can be done as you did.
Was a machinist back in 70’s and 80’s and then many shops went automated or closed down, mainly the latter so I went into where the demand was and that was in in heavy duty fitting. Chalk and cheese the difference you can imagine. Now I’m retired and it’s good to go back to a machining channel and virtually refresh my memory again.
I love you attitude about taking the time to do it right.
Like your work and your comfort level with the machine is a duly noticed.
Perfect sir. That lathe would have stories to tell of times so long ago.
Nice job, Keith. Another very informative and well executed video. The closeups on the cutter doing the work were just great. I could watch this stuff all day long.....
+Jeff Heath Thanks Jeff! Sometimes I do watch this stuff all day long. It gets boring after a while.....
@@VintageMachinery Many times I have wished that I could have a "fast forward" setting on the clock. Then I suppose it is like the guy in Catch 22 that tried to be bored all the time so he would live longer. Best to go with what God gives me. 😆
Thanks Keith as with most of your videos i learn something from everyone i watch
Thanks Keith. There's always something new to learn with your videos.
More great work Keith. Thanks for the update on when it is time to take the plunge and redo the braze. That kind of lesson is going to save a lot of us from having to fix something else that got broke because "close enough" wasn't quite the answer.
+hotdrippyglass Sometimes "close enough" is indeed good enough. Sometime is is not. The key is knowing when you need to start over!
Thanks Keith, it was a frustrating week and this made it all go away. Great lesson.
+Larry Pardi Thanks Larry!
Excellent work done. Most interesting to watch the work done by expert, and also explain technical information very well, it most useful for especially mechanical engineering personal, many many thanks thanks. My most lovely channel, also I am an engineer ( retired)
Great job Keith. I love learning though these videos. I have some broken cast parts I am going to fix myself instead of farming it out. Cool - Thanks
+Practical Metal It is worth the effort to do them yourself!
Nicely done, Keith! I'm a wannabe machinist and I have read (and watched) a fair amount about dividing heads. However, the fundamental way in which the tooth count of the gear being cut combined with the reduction ratio of the dividing head AND the hole count of the dividing head index plate all interplayed with each other escaped me until now. Thanks for the instruction!
Nice to watch a pro at work : ) I really enjoyed your video, Keith, and added it to my favorites. Take care.
+bush master Thank you!
great job buddy , love your work ! maybe too much heat ,smaller tip maybe ! I would use NI rod , but I stick weld , I weld alot ! Been a certified pipe welder for years , thanks for all the great videos
Great Video , You guys always amaze me on how you save items from being scrap .
+Rockland Kcorvic That's the goal!
Always great work and its a learning experience as well...so need one of these
Thanks Keith, I hope you have a nice weekend and get some well deserved time in the shop. Aloha...Chuck
+Knolltop Farms Thanks Chuck - hoping to get back on the furnace project in the morning!
Excellent craftsmanship... I'm ignorant on these procedures and I watched it out of pure curiosity. I'm impressed that the brass metal of the brazing method is capable of withholding the force applied onto it just like the other teeth which are cast iron.
Great job Keith, That,s the same way I do my broken teeth on a gear with that said it will last for years to come. Thank you for your great work, Stay safe
+Randall Moore Thanks again Randall!
You've probably made the Gear Truer than its ever ben. Thanks that wss a very good job☺
Great repair job Keith, gearing and gear repair are some of my favorite videos, one of my hobbies is making wood gear clocks, and restoration of brass clock movements. which involves knowing and understanding gearing, thanks for sharing My friend ..enjoyed
+TIM WILSON Thanks for watching Tim!
I really enjoy watching this show.
Now this is how the railway trades in Stratford Ontario would do it.. this is real skill..
HI Sr, FROM COLOMBIA SOUTH AMERICA I SEND YOU GREATINGS, THANK'S 4 TEACH US HOW REPAIR A GEAR. CONGRATULATIONS FOR YOUR WORK. JAKE a new fiend.
Sir, you are a real craftsman. Rebrazing that second tooth was a lot of work, but if it's worth doing, it's worth doing right. Great video.
Superb tech repair and slowly cooling down is the best way !
Great work there Keith, always a pleasure to watch a true Craftsman @ work!
+ShysterLawyer Thank you!
ShysterLawyer even the imperials stopped using imperial
Ritesh Patil Ummm, what?
ShysterLawyer b
Neat stuff there Keith! Always cool to see a big blob of bronze becoming a nice machined repair.
+Marin de Vree Thanks - it came out very nice!
Always good to Watch the Master At work keith. Ive been off the Air for about 7 Months moving from one end of the Country to the other, Finally Got My Computer up and running. Plus almost finished building my New Mobile Machine Shop (20 Ft Shipping Container) Which ill get some Photos Done Soon and put them Up. Dave from Australia
Just want to say, good job. Keep the old craft alive!
+James Bridges Thanks James!
Nice work Keith, and a great video. I was pleased you went back and rebrazed that section - I didn't think it was up to your usual standard!
+CornishMiner It was obvious once I cut some material out - you could see the inclusion inside. I really thought it was just where I did not build the braze up high enough at first.
Also, the one new tooth seemed a bit thinner than the original ones (38:03). Maybe just a visual perception anomaly in the video and angle but in going back to the video I still see it. This doesn't take away from my appreciation of the work especially since it was redone to a better finish.
I love those old machines. They just do what you want.
Beautiful video, Keith. I look your videos, very happy. Because what you're doing, that's what I learned lancer, the fitter (industrial mechanic specializing in industrial engineering). Greetings from Germany.
+Günter Schöne Thank you for watching!
It is really astonishing how well the brazed material adheres to the surrounding cast iron! If no one had ever seen that done before you would be 100% sure that the whole plug of stuff would come out the first time you ran the horizontal cutter along it. Yet it doesn't - and when finished the new tooth is perfect! *Fantastic* stuff Keith!!! To be honest I kind of hope your pal _does_ send it back to you as I'd really like to see you fabricate the whole gear up from scratch now! Many, many thanks as ever!
+morelenmir No worries, I will likely have some more gear work coming up in the near future.
Thanks for all the useful commentary!
I GOT INTO WATCHING YOU THROUGH WATCHING MY FAVOURITE, ABOM HE MENTIONED YOU SEVERAL TIMES SO I TRIED YOUR VIDEOS, REALLY AM ENJOYING BOTH OF YOUR CONTENT, GREAT TO WATCH AS WE ARE ON LOCKDOWN FOR THE SECOND TIME, THANK YOU BOTH.BOB U.K. ENGLAND.
Nice job and thanks for the time to show us how to do this job.
Thanks so much i have fought with this table and it is just like you say, hard to adjust. thanks
My childhood orthodontist could have learned a lot from you! 🤪 Great job, I’ve always wondered how that’s done.
Great work with the gear! :) I have done something similar when I repaired three teeths on the backgear of my lathe.
+tompas11 Thanks - how is yours holding up?
They are holding up just as I expected, in other word just fine. :)
Ha! Just saw your video! I learned these repairs in my early 20's, and I'm more than twice that now. I did "big gears" in Cast Iron that were about 20" in diameter, and the old expert I learned from was a guy named Bob. The largest "steel" gears I did were on "paper roll clamps" made for Cascade - I did those in 8620, and actually "hand machined" those with a handmade template I would use with "blue" painters oil paint. Never had a problem. Took a few hours to fix a few teeth. Piece of cake with someone with patience. Also used a 4" hand grinder with a 120 grit sanding disk and a hand file with "safe edges" . (The gear was worth more than $4k back in the mid 80's). Repaired for less than $400. It's amazing what the hand and eye can do with "blueing". Never had a failure. I found my old template sitting in my tool box the other day. Brought back fond memories when "hand skills" were still a thing.
Very interesting how you fix that gear, i have never seen anything like that good job.
+bluefalconcatering Thanks!
Finally!! Something worth watching on freaking KZhead.
Never knew that bronze could repair gear teeth. Great work!
20/39ths? my head hurts. Enjoyed watching this, thanks for uploading. Beautiful work.
Really interesting, you have some cool kit, thanks for the video.
How could anyone give you thumbs down? Could they be jealous? Shame on them.Just for that I had 6 of my friends come to give you more thumbs up. Excellent work as always! Thanks for the time you devote providing these videos for all to learn from.
+Mark V It does not bother me - there are a handful of guys out there that give every video I do a thumbs down. Who knows why...
Great vid. Your workshop reminds me of my grandads. And it's funny how you guys still use imperial. Thanks for the tuition though
You are an excellent machinist!
nice video Keith, thanks for sharing with us.
Always enjoy and learn from your videos- thanks.
How very interesting! Thanks for sharing Keith.
+Martin Thank you for watching!
Very nice, I’ve always have had interest in repairing broken parts by old school means using manual machines. Thanks Keith.
Every field can be made into an art. Sir you are a true artist.
+Bernard Carter Thank you for the kind words!
Really enjoyed watching and learning from this!
I always like to see skilled people working. :-) Nice video
I would have preheated it a bit more than lay in the root pass with hard bronze. Than turn down the torch for more control. It the cast has a crack in it, you drill a hole 1/2 inch past the crack so when the cast expands the hole trapps the crack , Vee it out and lay in the bronze. To cool it down slowly bury the part in floor dry in a steel container. This process works well on engine blocks as well. The big thing on cast is to stress relief. otherwise if it cools to quickly it can crack right along side of the weld or thru the center. To stress relief run a needle gun, (slag remover gun) or even tapp it with a round end of a ball peen hammer until its a cooled somewhat.
Looks like machines I used to operate. 1942 was a very good year!
Amazing. I miss doing this type of work.
Man I like them old tools man they get precision work done!, serious for a big fact
it always amazes me how much oil can be locked inside old cast iron.. you never think that it's actually somewhat porous until you start putting the heat to it and the oil starts seeping out. Man I miss brazing and welding.. I love the marshmallow like smell of most brazing fluxes... so good smelling (even though I don't eat marshmallows)
+J.A.Ratt85 Very true about the oil - I see that all the time!
It isn't oil inside the cast iron coming out (there might be some in the very surface layer but not inside) nor as another comment suggested water "sweating" out of the metal. It is the moisture from the water that is a combustion by-product from the acetylene flame, hitting the cold surface of the metal and condensing. Exactly like water on the outside of a glass. If the flame was hydrogen the reaction would be 2x H2 + O2 = 2x H2O and the ONLY combustion products would be heat and water; Because it is acetylene the reaction is more complex and there's other by-products, but there's still plenty of water there to condense on a cold surface. There's nothing coming out of the glass when moisture from the air condenses on it and likewise there's nothing coming out of the metal when moisture from the flame condenses on it.
Sorry Tano. The combustion H2O from gas torches condenses at a much lower temperature than this gear would have been at the stage of preheat where bubbles and fluids were seen exuding from surface pores of the Iron's crystalline structure. Yes, when using gas welding, water does condense on the surface of a cold metal work piece for a mere moment before evaporating off. H2O can't condense on a surface with a temperature over 100 deg C. It is entirely possible that an absorbed mixture of H2O and oil was present within the Iron, which has lived as a gear in a lubricated machine for many years. The H2O and then oils would have formed vapour and pressure, which drove the mixture to the surface, where some vapour filled bubbles were visible, the dark fluid spread quickly before evaporating or oxidising. If the pores beneath the brazed area were still exuding fluids and gasses, the brazing material may not bond to the surface. A possible reason for the mentioned inclusion in the 2nd area, which required re-working? Check- Super Oilite bearings (an extreme example) preheating Iron components before welding
@@VintageMachinery Cast Iron contains a small amount of Graphite, to make the cast more fluidic during casting. It adds a hidden benefit in that it will absorb some oil/water into the cast part. The metallurgic term is hygroscopic, although of it's light oils that are absorbed. This is why cast gears don't require a lot of lubrication and steel ones do.
great video, i would love to see the next video of the oil foundry series
+Mostafa Mohsen That is the next project to get back on - coming soon!
Nice work... Thanks for taking the time to make the video and share it
I once welded a new tooth (the original was broken completely off) using only GMAW wire on the base of a Telelect pole digger. The crew had been using the boom to wiggle the poles loose in the ground, instead of the correct way. Worked great, never saw that truck again.
didn't think brazing was that strong thanks for updating me
its really cool to see the metal sweat like that when you heated up the gear
Its not the metal sweating. It is moisture in the combustion by- products of the acetylene flame condensing on the (originally relatively cold) surface. Think a chemically more complicated** version of: 2 x H2 + O2 = 2 x (H2O) **more complicated because the acetylene burning is more complicated chemically than straight hydrogen, but it is a similar reaction which produces water as one of the by-products.
There's no water trapped in the microstructure of any metal -- steel, brass, bronze, or cast iron.
Older equipment ALWAYS works the best! And looks cooler!
GREAT JOB KEITH. GOOD VIDEO SHOTS. THANKS KEITH
+ROBERT HORNER Thanks for watching!
Great outcome, goes to show you take pride in your work with the re-braze, many a folk may have said was good enough at that point.
+Dinxsy imagine i fhe heard it failed sometime in future, he would be second guessing all the time about that inclusion and if it started to make it weaker, it takes pride in your work to be good at it, and to at least know you did the best job you can do, rather than half a job.
+Dinxsy Better to just do it right and not have to worry about things. If it had come back to me that way, I would not have been happy with the job.
Great video! Thanks for sharing! Hardly working that wheel cutter. At that slow feed rate it sounded like most of the teeth were just along for the ride!
Hello Keith, I didn't have a clue how you made that new teeth but after this video now I know how to repair teeth. Not that I could do it myself but I understand how it works so again a very interesting video. Looking forward to the next one and many greetings from Roel !
+RoelTyros As always, things for watching! I also thank you for your faithful feedback!