The biggest wheel on the Isaacs clock is a 120 tooth monster. As I said before, when I made the pinions I inadvertendly went from module 0.6 to 0.9 and I am unwilling to redo the pinions. I calculated that the biggest wheel on the clock it would fit on the lathe i.e. I could "swing" it. So it did, but this whole 120 tooth "great wheel" is a monster fully up to Godzilla's standards. I calculated that a 120 tooth wheel would fit the lathe. I had no idea how close that calculation was.
I cut these things out on the bandsaw. Then I turn them down to the exact diameter on the lathe. It is something like (N + 1.76)*M (M is the module and N is the number of teeth, and if anybody is screaming about this remmeber these are cycloidal bears, not involutes). As you can see it clears the little Taig by about 2mm and I had to file it a little to get it to fit!
Next we need a pair of backing disks for the wheel. I like the kind of board called masonite or its like. It does not matter if it is a lot off-center, its function is to support the wheel in its odyssey on the mill.
Now my dividing head has a height of 50 mm. Unfortunately at Module 0.9, the radius is about 110mm so I am a bit short. What to do? Why, riser blocks.
Above 100 tooth wheel for comparison.
A 100 tooth just barely fits without blocks. So... First I tried putting it on the left side of the mill. Note the riser blocks. Note the clamping. Also note I have not supported the wheel. Two big mistakes in one go. Unsupported Lexan wheels flex and lead at best to inaccurate cuts. At worst to "crunchies" where you wreck the wheel beyond repair. Worse yet, I am "climb milling." the cutter is fed in the same direction as the cutter moves. Sometimes this does not matter. On all the previous wheels it didn't. But this is a huge wheel relative to my equipment. So remove the vise, go to the right side of the mill.
Much better. Now I am "conventional milling" and the cutter moves opposite to the feed. I am still having problems. Stay tuned.
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