Machining Gears

We have a band saw that took a crap on us this week, a set screw came out and went threw the gears in the gear box and wrecked the teeth on them. So rather then buying a new saw I made the gears, I didn't have a broach for the keyway or did I have a dividing head so this is how i did it..

The bad gears

Making the blanks and broaching on the lathe

 The blanks and keyways all machined

The fixture to machine the teeth, here you can see we cut two gears together and located off the original gear.

Locating the first tooth

Almost there.. one tooth at a time

All the teeth cut

All blued up and ready to test run

After 30 min of running, now they are broke in. Clean the teeth back up and they are ready for heat treating

After case hardening

All ready to go back together