I don't think I've ever seen you happier than when you checked the gear and everything was great:) Your eyes were sparkling!

@MrAllister9

Жыл бұрын

The funny part is it pretty much is always perfect lol Love hows he's all into it though

@petermorgan1401

Жыл бұрын

Keith! Watching your videos day by day is better than a sit-com!

@msheaver

Жыл бұрын

After all the work, effort and setbacks involved in getting to this point, is Keith's joy not justified??? LOL Keith, we share your joy vicariously!

I would guess that in the machine shop of your youth ,cutting things like spiral gears was a mark of being a top machinist. It took years but you now are in that elite group.

@truckguy6666

Жыл бұрын

No doubt and consider not only the investment in time/apprenticeship but EQUIPMENT.. Just wow. I think this would be a REALLY high end well equipped shop in its day. $$$

@mrrberger

Жыл бұрын

@@truckguy6666 Still is high end equipment.

@jeffrey1312

Жыл бұрын

Gears get, and got, made on specialized gear making machines called gear hobs. Gleason and Pfauter are two brands I remember, but there are others. That gear would have been done in an hour in a gear shop. A former employer of mine sent me to gear school in Chicago about 25 years ago.

WOW! An incredibly complex setup. I hope the customer truly appreciates the amount of work it took just to get to this point.

An absolute huge amount of setup for a good result. Well done.

Thank you Keith for this wonderful and fascinating series of videos. Before you dismantle the machine setup, why don't you go ahead and make a run of those gears. Since so many thousands of Austin Sevens were built, many of which are still running, I expect there is a market for new timing gears. Of course you should also make the smaller mating gear that fits on the front of the crankshaft.

Excellent Job Keith! I remember cutting my first on a homemade CNC. writing the program in LinuxCNC to automatically do the indexing. lead and cutting etc... now for your next challenge ... Helical Bevel gears. the ultimate measure of a machinist.

Fantastic outcome Keith. The look of joy on your face said it all. I have watched all episodes of this task, and they were all a pleasure to watch. If you just showed us a finished spiral gear, and said "I made this, it's my first one", nobody would have a clue how much time, effort, research, skill, trial and error went into it. It's been an education, and an interesting one.

Keith, there is a difference between a spiral and a helix, they are not interchangeable. A spiral's diameter changes, from the center outward, and is typically in the same plane. The spiral in your 3 jaw scroll chuck that moves the chuck jaws would be an example. Whereas a helix typically does not change diameter. It is a line that runs around the diameter of a cylinder that progresses along the length of the cylinder from one end to the other. A helix viewed from the end, through its diameter, appears as a simple circle. People very often confuse the two and call a helix a spiral, as is the case of a spiral stair case, where actually the correct term should be a helical stair case.

The real praise goes to the men who designed and figured out how to make all of the mechanism to produce that very gear you just made. They didn’t have anything but a chunk of metal and an idea!

@johnmcanulty7341

Жыл бұрын

Reminds me of that phrase: 'We stand on the shoulders of giants.'

Up until that first cut, I couldn’t understand how this crazy setup was going to work. Then immediately it started I got it. It’s like alchemy. Magic. Fascinating stuff. Thanks for sharing.

@artszabo1015

Жыл бұрын

Yeah, what he said, me too. I have many years of machine shop experience and I still could not visualize this until, like you, I saw it.

@ericroth1741

Жыл бұрын

Likewise, I just couldn't figure it in my head until I saw it. True and proper engineers and machinists made this setup work.

@samrodian919

Жыл бұрын

And remember that this sort of set up was invented probably 120-130 or more years ago! Man those Victorian engineers both sides of the Atlantic were true engineers of the first order! When these things might have been only theory, these men went out and designed the machines to actually DO the work. Hats off all round I say!

Pretty darned cool to see how that all works after the great lead up with all the configuration of the mill. Congrats on accomplishing that first.

A great show of tenacity Keith! The setup is like poetry in motion. Don't forget that since this is a timing gear in an engine the position of the key slot could be critical!

Cut my machining teeth on machines like this making airplane parts at McDonnell Aircraft in St. Louis MO in 1958. Fun to watch you do what I used to do. We never made gears like what you are doing but we did very similar, tricky, setups to make airplane and space capsule parts. Sure enjoy watching you do what you do. You make excellent, educational, video’s. Thank you for going to the trouble. Jack, in Missouri

One of the neatest machining videos to date! A symphony of machinery! Nice going!

Keith is a national treasure for all of us trying to learn machining. His parents should be very proud of him.

Great job! What is more amazing, is the people that figured all this stuff over 100 years ago, with pencil and paper!

I have to bow to the engineers back in the day that did all the math and figured out how to do this. A complicated setup, and a lot of stuff needed in order to do it, but wow. Bowing to you as well for being able to decipher all that from the books in information and get it all to work.

As others have said: seeing the happiness and satisfaction in your expression at the end was really uplifting. So much prep, but a tangible, solid, excellent result. Thanks for sharing all of it with us! I'm eager for the real thing.

It is impressive that as old as that equipment is ,how little backlash there is in all of those gears and the lead screw.

Congratulations big man. Success on your first helix gear cutting. Job very well done. Great content.

Wow! You MEs rock! First, you had to decide to make helical gears, then do the math to figure out angles, depths, et cetera to make them work, then you had to make the machines to make the gears, and then the enclosures to hold the shafts and gears. And then, you do it backwards with no discernible damage. My hat is off to you, Keith! Congratulations!

One remarkable thing that can't be dismissed is the fact that all of this equipment was designed without the benefit of any sort of computer. No CAD. No solid modeling. Just a slide rule, a drafting table and a whole lot of brain power. Very impressive.

I wonder if, when you accepted that job, you realized all the problems you had to solve, parts and pieces you had to make or obtain and the changes in the machinery you were going to use. This is first time and it must have been rewarding at time and very frustrating at others to realize what had to be done to do this job in the usual Rucker style (Perfect). This has been an interesting project for those who watch and the educational value is invaluable. Thanks for another demonstration of the machinists skill. CNC machines do all this in a blink. I wonder how many "Machinists can do what you have done in your back-yard shop. The collections of machinery you have is a demonstration of the ingenuity of the industry in the USA. Thanks for the project, Keith. This has been a wonderful education in perseverance, dogged determination and ultimate success.

My compliments. As a side benefit, now, you have a incredible drink coaster. Thank you for the journey.

Rebuilding Lead Attachment - check! Machining new Shaft - check! Upgrading the Index Wheel - check! Changing to Universal Head - check! Being in Excel Hell for days - check! Seeing those first cuts must have put a huge grin on your face! Well done!

Many years ago I went into the engine room of the Queen Mary in California and saw these spiral gears that were several feet long. I wondered then how they made those and finally figured it out today when you said it would make a full revolution if you let it go long enough. I had not made that connection until then.

I couldn't wrap my head around how this worked...until you demonstrated it!

That's a great series and a great restoration of capability on the K and T mill in service of your subscriber's Austin Seven restoration. Fun to watch, and must have been really satisfying. But, for the record, it's a timing gear, and it doesn't mesh with its mating gear at 90 degrees, but rather on parallel shafts. The right test is whether the original and the test run mesh when laying flat.

@Bobs-Wrigles5555

Жыл бұрын

You are right about the parallel shafts, but your idea of testing the plastic gear meshing with the original gear won't work, two gears cut at the same 45 degrees will never mesh as the point of contact is 90 degrees out when they are in the same plane, try drawing the gear cuts on some toilet rolls (or something) and see why they are mismatched, you need a gear cut at the opposite 45 degrees to mesh when in the same plane. Which is why Keith showed us the way he did, the two identical 45s make a perfect 90 when meshed as shown and only as shown.

@walnutclose5210

Жыл бұрын

@@Bobs-Wrigles5555 You are right, of course - left hand mates with right hand helix. Thanks for the setting the record here straight..

Congratulations on your superb workmanship. How refreshing to hear you talk in thousandths of an inch. Over here we had the Metric System foisted upon us. At least in America you have stuck to the principle that “If it ain’t Broke Don’t fix it”. All the very best from “Old York” England.

@chipperkeithmgb

Жыл бұрын

Couldn’t agree more from a carpenter and joiner for the last 57 years from Oxford England

@wwtrkr3189

Жыл бұрын

😂 But it was broke! Basing a universal system on 3 grains of barley? You remember Whitworth, of course and the confusion that wrecked NASA's Mars landing? Never mind converting thousandths to fractions all the time. Even today the Americans use their own gallons. So much wrong with that antiquated system, and I work in both, depending on the measurements, the materials and which country I happen to be in at the time.

@cooperised

Жыл бұрын

I too am from York, England and do my machine work in microns. In the end it makes no difference whatsoever; the power of the metric system is in its consistent use of base 10, but if you're working in decimal inches you get that same benefit anyhow. Though outside of decimal inches, the gap starts to open up - I must admit I'm not at all sorry that I don't have to work with letter and number drills and all of that.

I still crack up in my head every time you say rinse and repeat, like we're shampooing the gear:)

The plastic one is what they would make today. Thanks for posting

@erik_dk842

Жыл бұрын

They also made them with plastic gears way back when

@ruben_balea

Жыл бұрын

Formica started to make phenolic timing gear blanks about 100 years ago and then a lot of manufacturers ended using them on their engines.

@erik_dk842

Жыл бұрын

@@ruben_balea Glad that that fact was brought on the table. Wink Wink

The setup on the mill works perfectly. 👍🇦🇺

Thanks Keith. I've finally got my head around what's going on here but it took some searching and reading up on Wikipedia entries to clear up some confusion between straight bevel gears and spiral bevel gears. Heck I didn't even know the term "tooth line" which in this case is straight but in the spiral bevel gear is curved. Gears seem simple but there's several competing factors to finding the best type for the application e.g. torque, noise, wear and axis alignment. An engineer could make a career out of nothing more than gear design.

@user-de8bu5es6f

8 ай бұрын

Back in the 1980s, thefe were several Teams of great engineers working to design gears. To make F1 boxes change much faster than a human with a stick.

Well done young man, set ups like that are above my pay grade but very interesting to watch.

Nice work Keith. Very impressive setup. Congratulations. Thanks for sharing. Take care, Ed.

Every time I think about complicated gears, I think about the Herringbone gears that they used in tanks in WW2 (Tanks that my Dad served it, actually!) and my mind goes into convulsions...... Clark cast a few, but until I saw that the tips of the "V" was either curved or interrupted, the machining of them just baffled me..... The Helical gear that you're making - I could see what needed to be done, and what had to happen to make it work, but going through all the details that the machine had to accomplish at the same time is just amazing. As several other commenters have said - my DEEPEST Congratulations to ALL the engineers and machinists who invented and made these machines that made this possible. Without them, we'd still be riding in Horse and Carts! And YOUR expertise in knowing how to use them, and willingness to show us, too, Keith!

@stuarthardy4626

Жыл бұрын

they are done on a machine like a shaper but with two rams one in/out the the other the same . very much like a Gleason gear hobing machine they had one at the Iron works that I served my time at only one guy in the machine shop used it 😀they did up to 24 inch dia gears on it spur and helical

@srfurley

Жыл бұрын

There’s a video on KZread of a large herringbone gear being cut on a special model of the Sunderland gear planer. These versions had ‘dh’ in the model name. Sunderland machines use cutters with a few teeth in the form of a rack; it’s easier to watch it in action than to try to describe it!

Keith, be interested to know how you found the centerline of the part to the cutter set at 45° from the axis of the gear. It's no problem finding center cutting a standard spur gear, but a spiral gear, not so easy. Back in my earlier years of my career in 1978, I worked on machines that cut long spirals on 30-foot-long steel bars. The spirals varied from 42" to 80" per revolution. We did it using DC motors and electronics. Ken

Very good and thanks for sharing. I had trouble wrapping my mind about how the helical gears were cut and seeing it in action really cleared things up.

I can’t believe how quiet the mill is!

amzing : all these tools were design and build nearly 100 years ago. Good thing that you mastered the concept and the use of all.

Well done Keith from a former scraper hand who hardly ever actually operated the machine tools I worked on!

Well done that man. Keith, lovely to watch the entire process , how the world has changed from powered by steam to pressing a few buttons.

Thanks Keith. That is a great series. The only thing I thought was that you could have shown the top edge of the first teeth which you cut too deep. It would be a good teaching moment for people watching. I remember 20yrs ago I cut a helical gear as part of a TAFE course (Trade College?). I managed to miss one increment by one hole when Indexing the part to the next tooth. The first indication that it was wrong was that the land on the top of the tooth was too narrow. So I had a 39 3/4 tooth gear! You did well. Theres a lot get right (or to go wrong) when doing helical gear cutting. That was fun, thanks. Look forward to seeing the real deal soon!

Timeless technology Fascinating to see an explanation on how to do it thank you for keeping tradition alive

Awesome job Keith, all about problem solving & overcoming challenges .... You've succeeded !!! Wonderful feeling !!!

Love this channel, been a follower for about a year now, also HI to all the Engineers out there, i`m not an Engineer myself sadly but my Father was so i inherited some of his love for precision and quality, i`m a 53 year old Kitchen Installer from the UK with almost 40 years experience who takes great pride in the quality and accuracy of my jobs, i`m also heavily into ancient engineering techniques, specifically how the so called Dynastic Egyptians cut and polished igneous stone like Granite and Diorite which has a Mohs scale hardness of 6 - 8, there are a good few Engineers out there now who believe, as i do, that these highly accurate monuments and statues were cut on machines similar to lathes and mills, the precision on some of these artefacts is to within 100th of a millimeter yet were are told by the mainstream archaeological community that they were done using copper tools, chisels and dolorite pounders BY HAND, anyone who knows Quartz, as i do as we use it for countertops, knows it can not be cut or shaped using copper or bronze tools to this precision, also under a microscope these objects don`t show impact marks which you would associate with chiselling and hammering, they are perfectly smooth, perfectly square and they even pass the light test with an engineers light test you can`t get that accuracy by hand, many of these artefacts show evidence of tube drills cut at a rate that we can`t replicate even with today`s highly advanced CNC machines, there`s evidence that huge 1200 tonne blocks and single columns were cut using a huge overhead circular saw and Live Centre holes in the bases of 200 - 300 tonne single piece granite pillars, there is an English Aerospace Engineer who moved to the States called Christopher Dunn, his qualifications are second to none in the field of Engineering, he`s travelled to Egypt and other locations around the globe and conducted tests on many of these artefacts and he`s concluded they had to have been cut and created using ancient engineering machines, something we are told never existed in pre history yet the evidence discounts that, there is a channel on KZread called UnchartedX presented by an aussie guy called Ben, his channel is dedicated to exposing these incredible highly accurate artefacts and calls for academia to acknowledge that there was once a long lost forgotten ancient highly advanced civilisation that existed before 12.500 years ago and was erased from human history by what`s known as The Younger Dryas Impact, a theory that has since been proven correct and it`s been peer reviewed, my big ask in all this to all you Engineers out there is to have a look at Chris Dunns work and Ben`s over at UnchartedX, see the evidence for yourselves when you get time and if at all possible lend your expertise and engineering knowledge to their work, the more skilled engineers who get on board the quicker science and archaeology will take it seriously, the theory is that in pre history there was a highly advanced global civilisation that had the knowledge and technical ability to build these ancient monuments and that the Dynastic Egyptians only uncovered, inherited and repurposed these sites thousands of years later once Earth`s climate settled down and human population and society was rebuilt, a big ask i know but i know these guys would appreciate your time and skilled knowledge to either agree with their hypothesis or point out errors in their theories, thanks for reading all this, i appreciate it cheers. Glen, West Midlands UK.

@MrMojolinux

Жыл бұрын

Yes! You summarized it all beautifully @Glen Claypool Smith! These Egyptian Pre Dynastic civilizations have yet to be out done in their mastery of fashioning not only Granite, and Diorite, but in quarrying, moving and accurate placement of enormous tons of material, that can not be matched even with today's modern machinery and equipment!

One of the most entertaining and educational channels on youtube. Thanks Keith.

I am surprised that you can back feed through that cut without lowering the knee. I really would have expected that even with a tight nut on the table feed screw there would be enough backlash in this system to make it rub feeding back through the cut. I am trying to figure out in my head if the backlash in the table feed actually compensates for the backlash in the lead attachment. Anyway, that is really cool, I can really empathize with the excitement and enjoyment seeing this gear emerge from the blank. The pride and satisfaction of a complex job done well. Congratulations.

@HH-Machining

Жыл бұрын

i am in a belief that any backlash would have effect when feeding backwards with this setup. Same as lathe leadscrew. It wont follow the same path, than going forward.

@fristlsat4663

Жыл бұрын

@@HH-Machining that was what I was expecting, but I watched carefully and I didn't see any chips from cutting on the return, hence my mental gymnastics to try to figure out if backlash in the feed screw would be counteracted by backlash in the lead attachment. Keith has been machining long enough that I know he understands backlash, and is observant enough to notice if the cutter was actually cutting on the back feed. I am just trying to understand why it didn't, unless the plastic was soft enough that you couldn't feel/hear it cutting on the very light engagement on the return path.

@HH-Machining

Жыл бұрын

@@fristlsat4663 I also tried to look out for some chips when backfeeding, but didnt notice any. This could easily be measured with existing setup and dial indicator. Maybe keith can explain or investigate this :)

Keith this is REALLY cool. Your down to earth explanations are excellent. This kind of thing looks so much easier when someone else is doing it! Anyone who has ever had to build complex things knows how tedious this is and how hard it is to make sure everything is perfect. The test cut was a good call. I am having a hard time wrapping my head around why the backlash in the table isnt affecting the cutter when you reverse the travel to pull it back out...

@michaelboyle1983

Жыл бұрын

It is affecting it. God bless you!

Awesome accomplishment! It's not an easy thing to even understand the setup, much less the entire process. I watched my grandpa do that 45 years ago on pretty much the same tools. At the time I didn't comprehend the complexity. It was even more challenging for him. No computers to help with the computations or videos to watch another master machinist demonstrate it. And to top it of us was self taught. He only completed third grade in school. The rest he did on his own! Lord I miss him!

@ydonl

Жыл бұрын

Great story! Hits home with me. Thanks for sharing that, John.

The amount of of mathmatical analysis to begin with, then converting those results into the proper set up and settings on the machine is intimidating. It is no wonder that more modern computer driven equipment has become so popular. My hat's off to you Keith. Very informative and the end product of a replacement gear for your customer will cost him more than his car if you add up your hours!

Really loving this series of videos!

Worth the wait! Enjoyed the process.

This is a fantastic series !

Well, folks…..there ya have it. A family heirloom for the display case! Outstanding work, Keith!

Thrilled for you, Keith. Well done. I hope when this is all done, the owner will send video of the car running so we can all enjoy it.

Great job! Love watching you work.

Very cool. Doing the test run was most definitely the right idea. Thanks very much for sharing.

Excellent especially as you worked out this complicated setup yourself as opposed to being shown how to.

Looks great, Keith. Thanks for sharing!

That was a beautiful test. Keep up the magic, Keith. Have a great weekend.

I think you should make 2 while you have it setup

Mesmerizing. Love the work Kieth.

This is so fascinating! I could watch this stuff for hours. Love seeing how things are made.

awesome work Keith. looks great.

Woo Hoo ! it's a gear ! Man what a journey since that first video when you found the lead attachment. Great results and accomplishment...now just one more step. See you next time...

When you explain how you get the part setup it adds so much depth and interest to your video. Thanks

So happy for you in your latest accomplishment. Well done!

Good to see you happy whit it.

This is awesome Keith, your content is an inspiration and has helped me through difficult times. It's great to see a big setup pay off like this!

Great setup turned out good, theres so much satisfying moments in machining.

Nicely done 👍. Thanks for the video Keith. Take care of yourself and family ❤️❤️.

This is a fascinating process to watch. Thank you.

Congratulations and thanks for all of your patience in carefully explaining a very complicated process.

Nice work Keith. Keep on smiling.

Thanks so much for sharing this process. It was a long piece of work to get to this point but well worth the effort

I am thoroughly impressed, your first time using a very complex, complicated setup, and once again you performed like the master that you are.

I love it when a plan comes together

Nicely done Keith! All your hard work and headaches getting all the equipment needed to do the job has paid off handsomely! Looking forward to you doing the job for real!

Awesome. What amazing knowledge and patience.

I always wanted to do this. Thanks for sharing.

So so so great!!!! Love this content. Thanks Keith!

Well done Keith

Great video Keith, excellent job, keep'um coming..

Congratulation! It was fascinating to follow you along the journey and I appreciate that you show us the process in such a great detail. It is challenging to do such a complex project for the first time - and you add the challenge of filming everything and explaining live! I did a project with similar complexity recently and attempted to put it on video. So I know from my own experience how hard this is. You are a real master, Keith!

Nice work Keith

Really good stuff Keith

We have a good friend who has owned a machine shop for 40 yrs. His biggest problem is finding people that can do a manual set up like that. Kudos to your ability.

@JW-qd4ig

Жыл бұрын

Hello Keith, Would you happen to want to share the spreadsheet with me for the math calculations? I would much appreciate the formulas laid out in easy to use program. I can send an email Thanks Keith

Well done Keith!

Nice job Mr Rucker! That’s quite an achievement for a small shop!!

A grin from ear to ear... great work!

The general public has absolutely no idea how much effort goes into making a part like this. You certainly looked happy. When it comes to the actual part, can you cut a half depth going in and the other half depth on the way out to save going round twice? I don't know about other machinists but when I cut a gear, I have to be locked in my shop with NO disturbances whatsoever. It's a very satisfying process.

@Bobs-Wrigles5555

Жыл бұрын

Doing the half and half is possible, But that would mean changing the table height "exactly" 60** times. I don't even want to think about introducing a missed step on any one of them...🤔was it up or down I have to adjust this time?😕=cutting air or double depth of cut ** If you have 30 teeth, do you have 30 "gaps" between teeth or only 29...

@passenger6735

Жыл бұрын

@@Bobs-Wrigles5555 Thanks Bob. It's a tough one whichever way.

Great video I enjoyed watching everyone of these videos on this job .

Hey Kieth, your video is reminiscent of a back in the day setup I had making a set of spiral fluted shafts on a B.&S. Universal horizontal mill. I think it was in 1969. Thanks for the memory jog. Nice work!

A treasured Moment, thank you for sharing it.

Thx for sharing this. Never seen it done before. I enjoyed it

ah!! awesome work Keith!!!! you been on it!!!

Very nicely done, perfect execution, good explanation too.

Such an awesome setup Keith! Intricate and interlocking. Gives you some real respect for the people who designed these tools. All without computers... Thank you for showing us!

Awesome! I’m ready for the real deal… way to go Keith!