Lets make a new gear..

[jedi-]

So the teeth on the new gear have valleys closer to the center point? That makes it modified oversize, and modified undersize would be if the valleys were farther from the center point? I'm also trying to figure this out by looking, and have never made a gear or even had a successful threading operation on the lathe (YET).

This stuff is very cool

Rather than go into details which would probably just be confusing anyway...take a look at the picture , the 8t gear on the right has been modified oversize or "corrected" and you can see how the tooth shape changes.
The gear on the left is 8 teeth also but its possible to put 7 teeth in that diameter and the center distance does not need to change at all to the rack. The teeth will now look similar to the modified gear on the right.
An advantage can be seen straight away in that the base of the teeth are very strong in comparison to the stock gear.
Most transmissions dealing with pinion gears(low number of teeth) deliberately
modify the gears oversize for strength
The Vmax transmission already has a bunch of modified oversize gears in it anyway. Al I did was modify it oversize even more for 5th gear

 

[jedi-]

Ummm sorry wrong picture and what happened to the edit function???


try this again...

 

[jedi-]

Wire cut the 6 tooth internal spline

 

[davesax36]

Ok, yeah. I saw the change in tooth shape and interpreted it differently. I'm just starting out learning machining techniques so this stuff is very interesting to me.

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[jedi-]

A bunch of pictures..
Roughly milled the drive dogs in the mill and then machined a copper electrode which has the internal radius to suit the drive dogs.
A cut off old Vmax shaft is used to mount the new gear on its 6t spline in the spark eroder so it can be indexed evenly 3 times for the 3 dogs.
This setup is tilted over 4 degrees in the machine being more than the stock Vmax gear angle on the dogs.
The dogs are also longer than stock giving slightly more depth.
A mock up assembly shows it all fitting together.
The gear now will be case hardened to about 59rc and then its good to go

 

[steamer97]

Jedi thanks for the telling

 

[jdeitz1979]

Looks good, hope everything holds up and doesn’t cause any issues, could be a new mod. Making you some extra coin.


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[jedi-]

Back from being case hardened , bead blasted and ready to go

 

[jdeitz1979]

That looks pretty good. When are you installing it?


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