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Webster IC Engine build log.
raynerd:
Hi Doug, thanks for your replies to my thread. I do appreciate your comments and your approach with a dremel was definately unique and clearly produced some nice gears! Since I`ve gone the route of gear cutting, I`d love to stick to the original plans and try and make the gears - part of the challange now I`ve started it.
Bogs, you were dead right, something had moved. I tried another few teeth on the dead blank and found the same. The full cut on the machine was just too much for such a small machine and it was vibrating loose. I do realise that my tool should be sharp enough to take the cut - or maybe not with just a single point? Anyway, I went with DeereGuys advice and went around first with a slitting saw, obviously of smaller width the cutter tip and to just a few thou short of the full cut.
This removed a good bulk of the metal and as soon as I swapped over to the gear cutter, I could tell cutting the first tooth that cutting was much smoother! The cutter did pick up a bit of a burr (I think perhaps I need to make sure my next cutter is a bit sharper)
I also used a much bigger washer to protect the little spigot but it also supported my teeth more even though it meant cutting into it. I don`t think I needed it actually but still, it seemed to work.
...and then cleaned up and put on some 8mm silver steel for a proud picture :ddb: I`m chuffed :D So just like the plans call for, a 48 tooth 32dp gear. I just need to make a 24 tooth gear that will mesh with it...I guess that is the real proof of the pudding!
Bogstandard:
Nice job.
Perseverance paid off this time, and now you should have no more fear of it.
You now know that you can make a cutter and cut a gear with it. It is just a matter now of fine tuning to get even more impressive results.
Bogs
dbvandy:
EXCELLENT job!!! That thing is perfect!!! My shop grows a new machine or major tool each week, so maybe I will come across a mill in the near future that wont break the bank so I can start cutting them like that!
Do you have an indexing head or just a rotary table?
very sweet job, sir.
raynerd:
Thanks guys, yes, perseverance has paid off! It is very much a case of learning and I really needed this one to work after so much effort. It looks OK to me but to be honest, the proof will be will it mesh properly! I certainly know a lot of improvements can be made on my next and perhaps I will have to come back and remake this!
Doug, the dividing index I have used was this: http://madmodder.net/index.php?topic=2242.0 - very very helpful in the entire process!
I`m going to get the other one made now asap, I`m desperate to see if it`ll work!
madjackghengis:
Hi Chris, that looks excellent, and as has been said, now you just have to fine tune your skills learned. I've done this for some forty years, and most of my education came out of books from the turn of the last century, at a time when machine shops routinely used lathes to mill, and made do with equipment at hand. Nothing we do as a hobby wasn't done for profit with less equipment and poorer tooling not so long ago, and the real tool that counts is what's between the ears. If you learn to make your own tooling, there is nothing made you cannot duplicate ultimately, and the skills developed on tooling will improve your work on the piece you are building, as the tooling always has to be better than the raw material you choose to hack out your parts from. Looking forward to that next gear, and moving forward with your Webster, a fine looking gear indeed. :beer: cheers, jack
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