A Multi-tooth Wheel Cutter and Successful Intermediate Wheel

My last three attempts at wheel cutting have been a steep learning curve. Not centring the cutter, not tightening the wheel, cutter not sharp enough….. A friend over on the Madmodder Forums offered to lend me a hand and so I visited his workshop and managed to make a multi-tooth cutter and cut a wheel. Here are the pics… The method we used I first read on an article by David Creed on making a multi-tooth cutter and also on Deans excellent website: http://www.deansphotographica.com/machining/projects/multipoint/multipoint.html

We have basically followed the instructions and ideas on there but here are the mandatory pictures!

This first one in my opinion was the most impressive. When calculating the tooth arc, we had to make a tool to profile the cutter to represent this arc. I had read that the easiest way of doing this would be to grind the end of a suitably sized drill bit as I have done and shown in an earlier log. Stew came up with an excellent idea of using a magnified projection of the tool to determine the correct size and profile. As you can see from the photo, Stew set up a torch, magnifying glass with the tool inbetween. This allowed us to project the profile onto some CAD drawings of the correct circle diameters. It worked very well and it was supprising how accurate this allowed us to be.

This shows the profiling tool ground to size and shape….. as you can see, it was in use at the time of the photo and hence all the swarf!

Here are all the arbours and jigs made by Stew…..and taken home by me…. THANKS I owe you one!

Another picture of the jig for drilling the 4 holes in the wheel blank….

Cutting the profile of each cutter side…

Cutting away the spare material of the cutter on the other jig…

The cutter straight off the mill…finally made!

And now time to harden! Cherry red and was knocked in a bucket of water:

The cutter mounted on the arbour and starting to cut the wheel. The wheel was mounted on my CNC divider which seemed to work quite nicely.

And the final wheel cut!

Thanks again Stew!


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3 responses to “A Multi-tooth Wheel Cutter and Successful Intermediate Wheel”

  1. Mark Peterson says:

    What is your current status? Any advances since July? I am curious to see how you end up on this project. This has got to be a labor of love. I endeavor to repair and restore at this time, but this is interesting to me none the less. Look forward to hearing from you.


  2. admin says:

    I appreciate your interest in this project. I have far too many other little projects on the go and have just had a major change around, reorganisation and machine improvement in my workshop that has really taken over the last month. I`ve just finished making a power feed for my milling machine which is going to be very helpful and then I want to sort out the play on my Boxford cross slide, adding thrust bearings and then I`m really going to hit the clock full time for another couple of months and see how far I get.

    I have to be honest and admit that after the 4th attempt at cutting a wheel, I got a little disillusioned with the entire project but now I`ve cut a good wheel I`m happy to continue soon. Probably another month down the line and I hope to progress further but at present I have nothing new on this project to report.

    I have learnt that I need to commit to one project a lot more than I do. That being said, I need to finish the few I have started before I make a fresh start and commit some time to the clock. It will happen…. I`d consider it my life ambition, hobby-wise that is.


  3. cyrus biscardi says:

    Good stuff, I too, make my own form relieved clock gear cutters so I know what you went through. Not many people are willing to go through all of that and then balk at the high price of Thortons cutters. Anyway, you can see my latest creation on you tube under Cyrus Biscardi Clock. As soon as the clockmakers newsletter “approves” me I’ll see you there. Best wishes Cyrus.

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