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

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.

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.

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

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!

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.

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.

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.

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

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

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

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.

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

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.

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!

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

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!

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.

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.

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

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.

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

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!

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!

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.

Can you imagine the work required to figure out this complicated interlocking tool arrangement and design the individual mechanisms and how they must interact to make that simple angled-tooth gear? Amazing!

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

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

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.

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

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

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

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.

The setup on the mill works perfectly. 👍🇦🇺

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

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 KZfaq 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.

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.

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

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.

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

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!

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!

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...

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

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

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

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!

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.

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

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...

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!

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.

Mesmerizing. Love the work Kieth.

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.

I can’t believe how quiet the mill is!

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

awesome work Keith. looks great.

I think you should make 2 while you have it setup

Nice work Keith. Keep on smiling.

This is a fantastic series !

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

This is really cool. I have never seen a helical gear cut like this on a milling machine. I knew you could do a spur gear like this on a mill or a shaper machine. This is cool to see a older manual milling machine setup and doing a job like this. I never seen a power table feed setup like that on a machine that allows you to us it as a pto drive. That opens up all kinds of possibilities for that machine. This is almost the same setup I would do when I ran gear making equipment. I used to run automatic hobbing machines for gears and shafts. But it’s really cool to see the old manual machines being used to it’s ability. Now days it’s all done with a push of a button almost. Don’t get me wrong CNC has a place but it’s not as enjoyable to watch as a operator and a manual machine when making something because that person is almost one with the equipment when they run it or you will make a mistake. You have to have that fill for that machine when running or you will never be able to produce a perfect part again and again. Great work I really enjoyed this.

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

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!

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

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

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

I'm just amazed at the men who designed all these things to work together like this. Do you have information on machine engineers that did the designing on the machines and indexing and feeds and all? I'd sure like to honor them if only in my own heart. It would be nice to at least know their names.

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

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

And that's the way it is done, congrats!!!. I remember back at school, the teacher made us, once a tooth was cut, lower the table, move it back, turn the divider plate to the next tooth, move up the table, and start cutting. Excellent job Keith!!!!

I love it when a plan comes together

Worth the wait! Enjoyed the process.

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

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

This was mesmerizing to watch. Gear and thread cutting are some of the most eye pleasing operations. When i do it, i can't enjoy it. I'm entirely too focused, but watching other people cut them is a genuine pleasure of mine.

Nice to see a machine with all the needed bits and pieces. Wishing the Cincinnati at work had that index setup.

Keith: Watching to making a trial part first is what I've always have done when making fine parts whether in metal or wood. I always start out with two pieces, the first is my trial part, the second is the actual part. I can't name the number of times that first piece was off a bit, or cut wrong, or some other mistake. When all the boo boo's are worked out then I start cutting on the expensive material. Much cheaper and less frustrating way to build or fabricate.

Too Cool!…….I hear the Navy needs a spiral cut gear for one of its ships…..it’s about three foot in diameter…… I think they should contact you😊😊😊😊😊😊😊 well done!

Well done Keith!

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

tons of patience !!!!!!!!!!!!!!!!! but it paid off !!!!!!!!!!!!!!!!!!!!! can't wait for the real cut !!!!!!!!!!!!!!!!!!

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

Looks great, Keith. Thanks for sharing!

I say your planning and determining the tools needed paid off in spades. good work!

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

Awesome job Keith!! :-) Cant wait for the finale :-)

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

GREAT "Online Teaching" for those that don't know! This WAS one of THEE greatest Machine setups I've seen on KZfaq! WAY TO GO KEITH!!!!

Keith that was extraordinary, I've never had the nerve to cut gears but after your demo I think I might try it.

I can not imagine how much design and engineering went into making the first machines that could cut bevel gears like that. And way before even the earliest computers. Great job Keith.

Keith I have very much enjoyed this series. I can't wait to see you turn the actual part. I don't think people actually understand what all goes Into producing an obsolete part.

Freaking spectacular. Its like a 5 axis CNC's grandpa.

This has been a fun journey.

You looked well chuffed Keith, well done.

This is a fascinating process to watch. Thank you.

This is important enough that the test article deserves a spot on the shop wall with a frame.