Subject: Re: Tooth repair

From: [email-masked] (Steve Rayner)
Date: Fri, 17 May 1996 10:15:08 GMT

I learned to do this years ago, as a standard clock makers & machinery 
repair method.
First, file or mill a slot where the broken tooth was. Next, file, or 
mill, a dovetail to suit.  Now for the new tooth.  Make a male dovetail 
on the end of some bar, that is a light force fit in the female dovetail.
Press in the new tooth blank, with a little paste solder smeared on the 
mating surfaces. These days you could use locktite. If you use solder, 
heat the whole gear until it flows.
To shape the tooth, I make a special cutter from a pice of annealed file 
( Never throw out an old, worn one ).  Machine a disk, a bit wider than 
you need, and profile it to a tight fit in the space between two good teeth.
machine away half the profile.   Now , file it to a snail shape with one 
cutting edge, and heat treat.
You now have a half tooth cutter. Rub the cutting edge on a sharpening 
stone, followed by an oil stone.

Mount her up, and cut half the tooth profile, turn the gear around being 
careful to check your setup, and cut the other side.

The result is a very strong repair
-- 
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     MY SECRET IS OIL OF HARLEY DAVIDSON !      Steve Rayner
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From: [email-masked] (Roger Mitchell)
Date: 17 May 1996 14:56:55 GMT

I used a similar process to fix a gear for a neighbor of mine who
shelled out the transmission in his John Deer 1010 crawler loader.
There were 2 teeth broken out of the low gear. I ended up cutting
a Dovetail joint where the teeth were broken and made a new piece
to fit into the dovetail slot. I made a template and ground the
new teeth to shape after putting the piece back into the gear and
using nickel silver rod and a torch to fix it in place. After
the operation was done, I re-heat treated the gear and we put
the transmission back together again. It has been running fine now
for over 5 years.
				Roger Mitchell
				Vp and Master Mechanic
				Ft. Collins Municipal Railway

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From: "John R. Johnson" <[email-masked]>
Date: Fri, 17 May 1996 11:25:59 -0500

Right Steve,  that is how you make a "partial plate" for a gear tooth!
It works well.  The only question is, is it worth while or can you just
order a replacement gear from Bosten Gear for less time and effort.  I
am the first to admit that sometimes you CANNOT and a fix like this is
the only reasonable way to restore a aged damaged gear.  If that is the
case, then this is the way to do it.
John