Waiting on new casting parts from Windy Hill Foundry

@@markhgillett Excellent, thank you. I have not been in the trade since finishing trade school and a toolmaker apprenticeship back in 1965, but watching you brings back a lot of memories. Thank you.

Dura-bar is beautiful stuff to work with. As an extrusion it is very pure and smooth, unlike cast iron. Try it. You won't believe you are working with CI!!

@@paulcopeland9035 The swarf tells the tale. It's roughly 1/2 way between what gray cast iron yields (LOTS of powder) and what steel yields. Graphite flakes = powder and graphite nodules = chips. Nodular iron is NICE stuff that even a non-machinist, like me, can appreciate.

It's one of my favourite materials to work with, well once your used to swarf everywhere and being as black as coal.

Why would it need to be "timed"? It is a simple drive gear.

That was my thought as well, though the level of precision required here can easily be achieved with a four-jaw (or otherwise adjustable) chuck. And it turns out anyway that one end seems like it will be held in the dividing head [chuck?], so now I'm all confused wondering when the centres are actually going to be used! I'll just have to stay tuned to the next exciting episode I guess! Something I have always enjoyed about Keith's channel is that he's happy share these everyday, basic jobs with us all over and over again. As an armchair machinist with future aspirations of having my own home shop, I find it invaluable to have the opportunity to watch over Keith's shoulder, so to speak, as he goes about his work. So many little details, like how a chip forms, how fast the work is turning, how the sound lathe motor changes pitch under load, the sound of the half-nuts engaging and disengaging relative to tool position, etc., etc. Observing these sorts of things once is interesting, but observing them hundreds of times is getting an education!

Agreed: Keeping the stock as one piece would have made for a better part, faster. Cut off to length and face the non-critical end after all the turning and boring is done.

Did you notice that the repaired tooth failed in the cast iron, not the braze? Speaks volumes to the strength of the bond in a brazed repair.

@@glenupp3407 The breaks in the gear look like shock loading of the teeth. I know nothing about this particular engine but it looks like the bull gear is part of the gear train to drive one of the wheels to propel the traction engine. I learned to fire and run a 10 HP single-cylinder Case traction engine in 1966. There were similar gears in the drive train between the engine and wheels for travel. Full-sized engines were geared to run at top speed to be about what a horse would travel pulling a plow.

Not a machinist but my thought is that a bandsaw blade is flexible so there may be some "wandering".

Did you bother to listen to the video? He needs the mandrel for the gear teeth cutting on the horizontal mill, so why not make it and use it for both.

@paulcopeland9035 No worries, brother. As we say, there's more than one way to skin a cat.

A couple videos ago Keith went over some of the projects he’s been working on and when he’s going to get to some of them. Check it out, it’s a good video!

55 06 dura bar

Me too!! Sunny Coningsby.

@@drewmog123456 👍 bomber county 😁

Abom has one under tarp in his old workshop, you can ask him if he wants to sell

I think they are waiting for a pattern made for casting at windy hill foundry

keep it cast iron as this is more of a sacrificial gear vs the bull gear which is way way bigger.

@@susannovotney1903 - Never heard of 'sacrificial gear' ... lol

@@NICK-uy3nl maybe I should have said it would be better to have the small gear to break rather than the larger one.

@@susannovotney1903 Neither should break, because it is as much labor to repair the small gear as the big gear and equal amount of machine down time. Cast iron gears belong to 19th century, this is a good opportunity to start converting the gears to modern steel alloys that weren't available back then

@@NICK-uy3nl It is good practice to make one part of a system to be the sacrificial one or the one that breaks to prevent the more expensive and/or complicated parts from being damaged if there is an accident in the series of parts. It would be like a shear pin on an outboard motor prop that breaks instead of something in the engine or other parts of the whole thing. The shear pin is relatively easy to replace if the prop hits a log, rock, or other hard objects while propelling the boat. A key is also a likely part to break or shear if a sudden impact load is encountered.

I thought the same thing, cast iron is just looking for trouble, unless they want that gear to be the "weak link".

@@garybrenner6236 A big gear for a wheel is very much larger than this gear by a factor of 6 to 10 or more. Not only would the large gear be more expensive to get and machine but the machines used to make it would need to be much larger also.

@@royreynolds108 I agree with that, I would have the smaller gear as the weak link. I've found cast iron especially Durabar is very forgiving and can take some accidental abuse.

Drew, I made a flippant comment about CI, but back in the day if you needed a lump of iron you got the foundry to cast you one. Recycle some scrap maybe. If you could make a pattern of your object, then you could have it. It’s really incredibly versatile, and low tech. Have a look at how Durabar is cast. Not the sort of thing you’d have in the factory foundry. In fact I think continuous casting is quite new as an industrial process. I certainly remember pioneering work on copper casting back in the late 1970’s. There was a cockup designing the runout rolls, the billet was too heavy to grip and it ran out of the die out of control. The cooling water was suddenly exposed to a ton or so of molten copper. The explosion took the aircraft hanger doors of the rails by about three feet. Took for ever to re fit!

@@johnsherborne3245 i understand what you say, but why make a new gear from cast which has to be susceptible to the same problems as the original?

@@drewmog123456 This part is much easier to repair/replace than the gear that it runs against. If you make this part stronger and something happens, then the part that fails is much harder to repair. You want the 1st part to fail to be the easiest one to work on.

@@mikewatson4644 BINGO!

@@drewmog123456 fair point. I think some one else suggested that this is an easier part to replace than it’s counterpart, but too, it probably lasted a hundred years, though it has had a few accidents. Maybe one should consider why it got broken and how that could be avoided.

Really? Down in the southern part of rural Georgia where there is very little in the way of machine shops and industrial activity? Sometimes it is necessary to pay a little or some more to be able to get what you want or need to be shipped to you instead of taking the time of traveling somewhere to get a better price.

@@royreynolds108 Really? Mcmaster carr is a mail order store. So ordering from them is pointless. Doesn't matter where you live. Your point makes no sense at all. And mcmaster carr isn't a "little" more expensive either, they are A LOT more expensive. Maybe you like wasting your money but I don't!

That hasn’t been my experience. In fact just the opposite. McMaster pricing and shipping are higher but I’ve gotten the correct parts and excellent service on every order; usually delivered in a couple of days.

@@onsecondthought4174 What did you not understand? Rural Georgia does not have a steel supplier on every corner. That piece of Dura-bar would be hard to come by in a lot of places. Sure, McMaster is mail order. That is the beauty of their service!

@@ellieprice363 Good for you. You want a brownie button? I own a machine shop pal, I purchased from them for years and had years of issues so because you purchase once in a while and not very often somehow you're right and I'm wrong? Is that it? Your little game isn't going to work with me chowder. Go fly a kite.