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  1. JackHB

    Spindle gear for Stark #4 Lathe

    So far, this is the only slide I've been able to scratch up. No idea what it came off of, but it's way more than beefy enough. Probably have to remove a considerable amount of metal to make any kind of reasonable fit.
  2. JackHB

    Spindle gear for Stark #4 Lathe

    Now there is a decent live center with a newly tapered shank.
  3. JackHB

    Spindle gear for Stark #4 Lathe

    Well, aluminum didn't go all that well The compound does not have enough friction to resist the torque when trying to cut metal. No problem with power. Waiting for some phenolic before trying again. Giving some thought to improving or making a better mount for hobbing. I'll probably have...
  4. JackHB

    Spindle gear for Stark #4 Lathe

    Ran a couple more tests in plastic, but decided to improve the rigidity somewhat by reversing the hob mandrel and setting the slides for maximum overlap. This meant reducing the travel to 2 inches, but that's just a bit more than enough. The next attempt will be with aluminum. Forgot to...
  5. JackHB

    Methodologies for one-off gears in an antique home shop

    Here's a shot of the kludge hobber on a Stark lathe as documented elsewhere on this site.
  6. JackHB

    Spindle gear for Stark #4 Lathe

    First gear test in Nylon (?). 54 teeth, a little deep (~ .100"), fed at .025" per turn. The angle needs to be tweeked. I need to find a better way to set it. Fuzz has to be removed on the back side. Changed the mount to use the Stark compound. Very old but in better shape than the...
  7. JackHB

    Spindle gear for Stark #4 Lathe

    A very pleasant surprise ! The clocks in the SX drives are so good that all one has to do is set the speeds of the 2 steppers independently and they stay in synchrony. No programming, just calculate the ratio for the gear setup, plug in the speeds and go. This has only been tested w/o...
  8. JackHB

    Spindle gear for Stark #4 Lathe

    The cobbled up drive system for the 2 steppers. Monitor, cheapest PC I could find, now running XP w/ free software from Parker, ( XWare )and 2 surplus SX drives. This is what was available for a temporary fix. It will be an involved calculation with all of the belt and gear ratios being used...
  9. JackHB

    Spindle gear for Stark #4 Lathe

    With a fair bit of frustration finding time to work on it, and a small rush job which needed the Stark, it looks like the gear drive is the best so far. No tension between the shafts to account for. This is probably not the final pair of gears (or belts) but it seems to work well enough to...
  10. JackHB

    Spindle gear for Stark #4 Lathe

    The new stepper seems to have enough torque to do the job, enough to make the timing belt slip. To counter that, another new extension for the mandrel has been made on the Stark, this time much more carefully as the compound is very touchy. The drive for the mandrel is being switched from...
  11. JackHB

    Spindle gear for Stark #4 Lathe

    Progress on the gear cutting is very slow. Still need to find a good stepper for the secondary axis. The gravity mount and the spindle stepper drive has been working very well. The same mount should be fine for the DC motor in the future. Slowly building up a 4S collet collection. Edit...
  12. JackHB

    Spindle gear for Stark #4 Lathe

    Setting the hob angle of 1 degree, 28 minutes. A 1/16 pin is superglued to the Rivett alignment block to gauge the angle from the block corner using the trig tables. Mandrel to mount series of gear blanks and trim the diameters.
  13. JackHB

    Spindle gear for Stark #4 Lathe

    4S collet plug number 2 also made from a cutoff piece of stainless ball screw. Before... After... The thread came out much better this time, but the newly acquired die would not start on this material w/o cutting a rough thread. Burred like crazy. The die was more like a self-correcting...
  14. JackHB

    Spindle gear for Stark #4 Lathe

    The setup w/ a 70 tooth gear for lineup. It looks like the 66 tooth gear may be the minimum tooth count for this configuration as it stands. It should be able to get to 127. Replacing the compound w/ a direct mount is one possibility for smaller gears, inverting the setup may be another...
  15. JackHB

    Spindle gear for Stark #4 Lathe

    The setup w/ a 70 tooth gear for lineup. It looks like the 66 tooth gear may be the minimum tooth count for this configuration as it stands. It should be able to get to 127. Replacing the compound w/ a direct mount is one possibility for smaller gears, inverting the setup may be another.
  16. JackHB

    Spindle gear for Stark #4 Lathe

    Inside the 4S collet-mounted chuck... There is a ring shaped cam that rides on the back of the ring gear to engage or disengage the the chuck jaws. The cam is accessed through the slot on the back face of the chuck. There probably was a threaded pin and a thumb nut there originally. I...
  17. JackHB

    Spindle gear for Stark #4 Lathe

    Update: slow going... Bored the arms for bronze bushings. This went well using the original shafted piece to line up the holes in the drill press. The shaft itself has been a problem. The extension threaded on the end still has a wobble. This will have to be redone. The lathe...
  18. JackHB

    Spindle gear for Stark #4 Lathe

    The support arms keyed and fitted to the milling attachment. Need to fit the gear blank shaft next. (the disk is just for illustration)
  19. JackHB

    Spindle gear for Stark #4 Lathe

    A quick Trim-N-Shim of out of round on the backplate reduced it's OD by .022" and shimmed with .010" material greatly reduced the chuck offset.
  20. JackHB

    Spindle gear for Stark #4 Lathe

    The gear blank holder (shown w/ gear) as carved from pneumatic cylinder piston shown above. Reusing scrap parts can save a lot of time (esp. on a WW lathe) and often means better material. The 4-jaw chuck needs a new backplate, the imbalance that it causes is a pain to work around. There...

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