Have you looked in the bottom of the cover as they often pack a spare gear there ?

Edited By John Stevenson on 11/02/2015 14:46:22

I suggest you contact HPC gears of Chesterfield their phone number was 01246 268080, but you will need to know the gear technical details.Ted

Manuals for Align power feeds are here. Include exploded view, parts list etc.

If it's the ubiquitous AL500, part number 102 looks suspiciously like this gear.

Where do you get spares in the UK? The Auction Site?

Yes got one of my spare gears here 107 teeth 91.3mm OD and a tapered hole in the centre 42mm on the smallest diameter.

If you lay a protractor across the teeth and let me know the angle I can attempt to 3D print you one early next week.

I do have some decent gear software to work all this out.

Neil,

How are you working out the DP ?

Because without knowing the helix angle none of the quick add two teeth formulae work.

As an example 108 teeth 30DP 10 degrees helix  gives an OD of 94.5mm

Increase to 15 degrees and the diameter increases to 96.35 and at 20 degrees helix it's now 99.0018mm OD

Edited By John Stevenson on 12/02/2015 14:50:26

Quillstar in Nottingham have been selling new Zytel gears for the Align power feeds for a few years, they are currently £35, but I think they are 107 teeth.

OK peeps, working off what we have as regards number of teeth, OD and we take the pitch angle as 15 degrees which sounds reasonable as they often work in 2 1/2 degree increments for some obscure reason.

The DP works out as 31.42 but more telling is the Module at 0.81 which we will ass-ume is 0.8

Now i don't mind having a go at printing one of these but my printer, UP!2, can do various densities as regards fill but it cannot do a complete fill. Probably as it uses to much filimant and / or takes too long so

[a] Not sure how strong it will be, and

[b] not sure what the tooth detail is like on something as fine as 0.8 mod but prepared to give it a go.

Alternative is to hob one but not sure if I have a 0.8 Mod hob and if I have I will have to make mandrels etc for it as I'm fixed on 1" or 1 1/4" bore hobs, not 10mm ones.

Alternative is to mill one using Gearotic which allows you to cut involute gears with an end mill, no special tools.

Drawback to this is the size of cutter needed, according to the screen shot it has to be smaller than 0.6 mm