Alan.

I used a slotting head and rotary table on a Victoria mill for a Bantam gear.

Emgee

Have done similar by careful selection of drills to clean out most of the metal for the spline spaces before removing the centre bore and squaring out the corners using the mill, or drill, quill slotter fashion with the spindle stationary. Final clean up to fit with file(s). Two small drills to define the corners and a lager one to remove most of the space worked for me. For this sort of relatively light duty, I assume these are extra gears to extend the screwcutting range, its safe to take a few liberties with fit. If the centre bore is accurate the gear will sit cleanly on the shaft so a bit of clearance at the tip of the splines is OK. If you set up first with a master and note the settings before doing the slotting bit its not that hard to get adequate engagement on the spline sides.

Tedious and certainly a shut the door and put up the Danger – Model Engineer at Work – Don't Disturb sign tho'. I only had two to do and that was quite enough thank you. Worth a measure up and investigation to see if matching splined sleeves can be got reasonably priced from outside suppliers. I recall hearing of a similar spline matching problem deep inside a lathe (Holbrook I think) being fixed with a standard splined sleeve from an agricultural engineering supply place for around a tenner. HPC and other "proper" engineering suppliers seem to want £100 upwards for precision splined bushes which isn't viable.

Clive

Edited By Clive Foster on 12/10/2015 21:32:29

Hi Alan,

Firstly I must say that I am a dealer. I have four of the five gears you are looking for (36, 49, 57 and 69). These are used original Colchester parts.

If you're interested send me a PM and I'll give you my contact details.

Jim