Gear tooth repair

This collection of pictures show the method I used to repair a broken gear tooth on the feed pinion on an old F.E. Reed lathe.

Picture #1

This shows the result of machining off the rough surface that was left after the tooth broke.  I had degreased the gear first, but by machining the surface I knew it was even cleaner.

Picture #2 and #3 

Here are two views after I drilled and tapped for studs.  I used a tapered tap and stopped short so the stud would not go all the way through.

If I had to do it over again, I would wet the cut surface of the gear with the brazing rod before tapping the holes.  With a MAPP gas torch it was not hard to braze the studs, but it was hard to braze the cast iron with out melting the tips of the studs.

Picture #4

Here I have installed the studs.  I used stainless steel screws I had and just cut off the heads.  I verified that the brazing rod would "wet" the stainless screws first because I was not sure they would work.  I was not worried about length at this point
Picture #5

	After Brazing.  Not very pretty, but it worked.  Again, if I had pre-brazed the cast iron before tapping it would have ended up looking a little better (I think).

Picture #6

	Oops, forgot to take a picture after machining, but you can see what it looks like reinstalled in the apron of the carriage.

	When I machined the gear tooth, I borrowed a cutter from a friend that was close, but not quite right.  So I used several cutters that were right for different parts of the gear.  I moved the cutter so it was "tangent" to, or just touching a good tooth, 
	I'm happy with the results, though I have not installed the carriage on the lathe yet.


I hope this helps someone else.

Vince Iorio