Cutting a Gear with big Challenges

This gear is a DP8 with 62 teeth, its 8” in diameter, and it has six spokes with a hub, a 1 1/8 bore, and a 3/16 keyway. It's the most difficult gear I have cut, and the methodology is somewhat unconventional, but it just worked, even with a dull cutter and a lack of rigidity in the casting. There are a few issues to overcome along the way and some interesting lessons learned for future gear cutting projects. Additional support is required for the Milling ,and I made a call to gash the gear. There's lots of machining on the Colchester and a whole lot of milling. This is a collaboration project with my friend Shane to make a replacement gear for a 1908 REO Vintage Car. Please like the video and don't forget to subscribe and help my channel. #milling #turning #hfcreators Timestamps 00:00 Introduction 00:24 The Finished Gear 0040 The Pattern 00:55 Parts List 01:15 The Gear Plans 01:25 Setting the Tool Height 01:40 Aligning the Casting 02:10 Machining the raw Casting 05:45 Installing a Spindle Adapter 06:40 Installing a Divider Chuck on the Lathe 07:10 Dialling in the Casting 08:00 Turning the other side of the Casting 09:40 The Gear Specifications and Calculations 10:00 The Mill setup and Centering the DRO 10:35 Proof Marking the Gear 11:30 Setting the Height of the Gear Cutter 12:00 The First Cuts 14:15 Second Cuts 15:15 The First Gashing 16:50 Removing the Burr on the Colchester 17:20 Resetting up the Chuck in the Divider 17:35 The Second Gashing 18:40 Setting the Cutter Height for the Gear Cutter 19:45 The First Profile Cut 20:30 The final Profile Cut 21:30 Finish Machining the Gear - Boring the Hole 26:00 Removing the Spindle Adapter and fitting a 4 Jaw Chuck 26:40 Dialling in the Gear 27:05 Finish Machining the Gear - Facing and Sizing the Boss Side 1 28:45 Finish Machining the Gear - Facing and Sizing the Boss Side 2 30:40 Cutting the Timing Mark 32:00 Cutting the Keyway 34:10 Filing the Edges of the Keyway 34:50 Final cleaning up with a Dremel and File 36:45 The Finished Gear 37:00 Final Photos 37:45 End Useful Affiliate Links: Affiliate Discount Links for VEVOR Machine Skates: US: https://s.vevor.com/QTYPHL AU: https://s.vevor.com/QTXWU6 VEVOR Ultrasonic Cleaner Discount Links: US: https://s.vevor.com/QTXWVP AU: https://s.vevor.com/QTXWWD CA: https://s.vevor.com/QTXWWQ EU: https://s.vevor.com/QTXWWY