9 inch Ford differential in 1/3 scale

[Don1966]

Awesome George, I hope when you do the metal gears that you give us a blow by blow of how you went about doing it. I am very interested in the results and how to.

Don

[ozzie46]

  OOH BOY !!!  Here we go again. Another fabulous ride.

 I always learn from your threads George. Along with the other great minds and hands on this site.


 Ron

[Maryak]

Glad that's working out for your George!

Dave

What Dave said + 

Best Regards
Bob

[metalmad]

Hi George
Making the trial gears out of corian is a top idea.
Will be following along as always.
Pete

[sbwhart]

Looking good George 

Very interesting project it certainly stirs up the grey matter.

Watching with great interest

Stew

[BillTodd]

Great George


Helical and spiral gears are a major pain to model/make at any time.

 I've only made them in pixelanium (which has the big advantage of very quiet meshing regardless of tooth shape )

The crown wheel teeth were produced with a circular cut - which looks eminently do-able in metal

(I cheated with the pinion, by twisting a straight one . The model was only for illustration)

Bill

[ScroungerLee]

That's very nice George.  You always have the most interesting projects.

[Dean W]

Just lookin' at the pictures, mouth hanging open.  Same as with all your
threads, George.   
What an undertaking. 

Dean

[gbritnell]

Today was the big test, metal! The pinion is brass and the ring gear will be steel. My reasoning behind this is twofold. One I will have 2 different metals working against each other and two, the pinion will be almost hidden down inside the housing so almost everything will look like steel.
I first turned the pinion blank to the proper dimensions and angle. It was moved from the lathe to the dividing head. The first step was to indicate it concentric. Next was to set the center of the part. I picked up the turned area of the shaft with an indicator and transferred that to my small height gauge. I then subtracted the radius dimension. The center of the cutter was then set to center and it was moved in to lightly touch the pinion blank for setting the depth. I started out going to the full depth, .086, but there was quite a bit of pounding so I backed off to .065 and it wasn't as bad. I then went to the full depth.
The procedure for cutting these gears is to make the first pass, flip the cutter over, reset the height and make the second pass. As I learned from doing the plastic version it left a fin down the middle of the cuts so a little burr and file work was necessary. Once everything was cleaned up I gave it the lathe test and it seemed to run quite nicely against the plastic ring gear.
Tomorrow will be the steel ring gear. I think I'll see if I can sneak a slitting saw through first to at least lessen the load on the blunt fly cutter.
gbritnell
Pic 1.  The blank
Pic 2.  Setting the cutter to center
Pic 3.  Touching the blank for depth reference.
Pic 4.  Resetting the cutter for the first pass.
Pic 5.  The finished gear, filed and cleaned up.

[zeeprogrammer]

Gee whiz George. That is simply awesome.
How long did it take to make?

[ScroungerLee]

Amazing work.  I am looking forward to seeing how steel works out for the ring gear.

[Don1966]

Nice work George and please keep the photos coming. Awesome project to watch come to life.

Don

[steamer]

Yes !   More photo's of the set ups would be very nice!

Dave

[Mosey]

Inspirational! More!

[Tennessee Whiskey]

Let's see  302---4speed----9" rear---1/3 scale. So what will be the wheelbase of this Shelby when frame and body build start. Beautiful Stuff!!!
Eric