A viewer asked if I could help him by repairing a broken tooth on a back gear off of his South Bend lathe. Instead of brazing it up and cutting a new tooth, I decided to go at things a different route. This time, I milled the old tooth off and cut a pocket underneath it. I then machined some cast iron to have a piece that I could silver solder into the pocket to form a new gear tooth. The part was machined on the lathe first to get everything round again and then a new tooth was formed on the horizontal milling machine using an involute cutter and dividing head.
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