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Made An Axle On My Table Saw


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#1 New.Canadian.DB.Owner ONLINE  

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Posted November 14, 2014 - 06:27 PM

In fairness, I also needed my radial arm saw, drill press, and angle grinder.  

 

Some of you may remember that I spent $240 to have an axle made for the Supremacy 45 I accidentally started to restore when I found the crankcase full of water.  Lauber1 suggested I should get some access to machine tools, so when I decided to replace the axle on my Waterloo 15 (bad groove at the oil seal) I started looking around.  I figured I would need a milling machine, but they look like my drill press.  That got me thinking that my radial arm saw looks like a surface grinder.  I have used the table saw to make dadoes in wood projects.  Metal is just really hard wood, right?  Both are carbon based.  

 

So, anyway, I called around & found 1" cold rolled 1018 round rod for $4 a foot.  They have a $15 minimum, and I needed 26.5 inches.  Quick math & I bought 9 feet (4 sections, no waste, gotta have a spare anyway).  It came as 2 pieces, each 4 1/2 feet long, so I used the radial arm saw to cut one of them into two pieces 26.5 inches long.

 

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I made a jig out of some wood, not the best choice, but it is what I had. 

 

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I secured one piece in the jig and drilled the hole for the drive gear setscrew.  I then flipped the drill guide over & locked the axle into the jig with a 1/4" bolt through a nut I had welded onto it. 

 

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From there it was off to the radial arm saw with a 3/4" fine grinding wheel.  That made the flat spots on the ends of the axles where the locking bolts ride. 

 

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Then it was off to the table saw to cut the key way groove for the clicker hub key.  I used two 1/8" cut off wheels to make the 1/4" key way. They left a small ridge down the centre, which I cleaned up with an end mill in my drill press.  My angle grinder cleaned up the run-out portion of the keyway. 

 

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That's where the easy part ended.  The keyway for the drive gear is directly below the bolt I had installed to lock the axle in place & maintain the alignment of all of the grooves & flats.  To spin the axle 180* and keep the alignments spot on, I drilled a hole through the drilling guide & out the bottom of the jig.  When I rotated the axle, I slipped a 1/4" pin into the hole from the bottom and into the drive gear setscrew hole.  While I was turning the axle I marked the location for the drive gear keyway.  Then it was back to the drill press and the end mill to make the keyway.  The original axle used a woodruff key, but I went with 1/4" square stock rounded on the ends.  I dimpled the lip of the set screw to keep it from loosening off.

 

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While I had it apart, I figured I might as well make some new clicker springs for the ratchet hubs.

 

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It is all back together and runs like new.  Time will tell if the oil leak is fixed.  Now I can get back to the oil leak on my Allis HB112.

 

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#2 HANKG OFFLINE  

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Posted November 14, 2014 - 06:47 PM

Clever approach, using what's on hand keeps money in your pocket.


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#3 Auburn David OFFLINE  

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Posted November 14, 2014 - 07:07 PM

Difference in a mechanic and a parts changer!


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#4 KennyP ONLINE  

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Posted November 14, 2014 - 07:09 PM

Nice approach to making the axle!


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#5 tater195 ONLINE  

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Posted November 14, 2014 - 07:14 PM

I would have tried an angle grinder.

Nice job on the keyway!!!


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#6 massey driver OFFLINE  

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Posted November 14, 2014 - 07:21 PM

Nice job with using tools what you had on hand to get the job done.It's amazing what we can do with the tools that we have. Goodwork.


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#7 KC9KAS OFFLINE  

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Posted November 14, 2014 - 07:28 PM

Very clever! Great job on the axle.


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#8 Alc ONLINE  

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Posted November 14, 2014 - 07:35 PM

Great Job !! What away to use the tools you hand on hand  !


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#9 IamSherwood OFFLINE  

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Posted November 14, 2014 - 07:59 PM

That's using the old noodle Mark. :thumbs:


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#10 lyall ONLINE  

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Posted November 14, 2014 - 08:01 PM

good use of the brain power to think it through


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#11 gopher OFFLINE  

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Posted November 14, 2014 - 08:02 PM

Just a side note. BE VERY careful when putting cut off wheels on saws that might have higher rpm's then blade rated. Could be really  bad outcome.


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#12 olcowhand ONLINE  

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Posted November 14, 2014 - 08:21 PM

Very nice work with what ya got.  I figure it'll seal fine, as there's no reason it shouldn't.  :thumbs:


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#13 trowel OFFLINE  

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Posted November 14, 2014 - 08:33 PM

Wow mark, that is clever as all heck, I love the saw idea !


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#14 Gabriel OFFLINE  

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Posted November 14, 2014 - 09:21 PM

Nice work!

#15 Lauber1 OFFLINE  

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Posted November 14, 2014 - 09:26 PM

I knew you could make one your self, it just takes some out of the box thinking sometimes.


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