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Off Topic Off Topic - General non-Corvette related discussion. |
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01-20-2018, 9:00pm | #1 | ||||||
Barn Stall Owner #327
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metal stitching for repair ( pics and explanation )
My friend Bill Hazzard does metal stitching repairs as it's needed at times to save various parts of old engines.
The gear is off this 1890's Otto engine that my friend Roger purchased in the early 1970s. There aren't too many of these 17 hp Otto's left plus it's best to keep the engine as original as possible. Here is the gear on the crankshaft. It turns the larger idler gear which is attached to the angle gear which turns the sideshaft. Think of the sideshaft as the cam as it controls opening of the valves and the timing for ignition. One more view of the gears from the back. You can see the damaged tooth. Also notice the "feet off" cast into the base. As the engine turns in a clockwise rotation as viewed in the above picture, if you would put your foot there when starting or running and "bad things would happen quickly" Someone had done a "repair to the damaged tooth by drilling and tapping two bolts into the gear tooth area and filing them to approximate shape. The bolts from rocking back and forth created a fracture in the hub. Since the crack only went a short distance into the casting, a single row of stitching was used. Here is the gear with the drilling fixture where the repair goes. The gear is 5.812 in diameter with a bore size of about 3-1/2" inches. The gear after being drilled 1/2" deep for the "Lock-N-Stitch locks". It's sitting on Bill's 130 year old Peter Wright anvil that he used to back up the gear when he drove the locks in. After being flat filed to match the original surface height. Once Roger has the gear back, he will bring it to my work and I'll have the inspector measure one of the good gear teeth on the CMM. He's lay it out of the computer and we'll use that to cut a single tooth on the waterjet. The bottom of the tooth and the broken portion of the gear will bot have dovetails cut into them. The original gear was cast and has the flat "washer" on the back so it would be extremely difficult to cut a new tooth in a conventional way. Jeff |
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01-20-2018, 9:55pm | #2 | ||||||
Barn Stall Owner #13
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Amazing work as always!
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01-20-2018, 9:56pm | #3 | ||||||
Barn Stall Owner #327
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01-21-2018, 5:08am | #4 | ||||||
Barn Stall Owner #13
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I’ve not heard of metal stiching before but I’m guessing the idea behind the shape is that it helps lock the joint together
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01-21-2018, 5:28am | #5 | ||||||
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Was that filled in with welding rod or something of the like, or was a plug just beat into it?
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01-21-2018, 7:48am | #6 | ||||||
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Pretty cool; I've never seen that before.
How does the missing tooth get repaired? |
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01-21-2018, 7:15pm | #7 | |||||||||
Barn Stall Owner #327
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Quote:
Quote:
The plug(s) and driven into the drilled pocket and expand to fill every crevice. Quote:
Then it will be converted into a .dxf file and a tooth will be cut on the waterjet. The bottom of the tooth will have a dovetail cut into it and then the same dovetail will be machined into the gear for the new tooth to fit in. It will be a light press fit plus it ill be captured between the crankshaft and the flywheel once it's assembled. After much discussion with Roger, Bill , Wayne Grenning and myself, it was decided that would be the best repair to save the original gear. |
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01-21-2018, 9:11pm | #8 | ||||||
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Doesn't that stitch leave the ends of the existing crack and thus not alleviate those high stress points? Seems like it would allow crack propagation to continue.
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01-21-2018, 9:15pm | #9 | |||||||
Barn Stall Owner #327
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Quote:
The lock stitch repair will hold the gear together and not allow any forces to continue to expand the defect. |
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01-21-2018, 9:48pm | #10 | ||||||
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Interesting. What are those things called? And what the heck are they made of?
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01-21-2018, 9:56pm | #11 | |||||||
Barn Stall Owner #327
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Quote:
You can use either "locks" or "pins" depending on the type of repair needed. Crack Repair Tools & Supplies On Lock-N-Stitch A bigger repair to a part would be done by having the company come to your location or sending the part to them. |
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01-22-2018, 10:16am | #12 | ||||||
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Will the dovetailed tooth have a set screw? Or will the dovetail be snug enough to keep it from moving out?
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01-22-2018, 11:00am | #13 | ||||||
Sparkles Flambeaux
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in woodworking, a similar repair or patch would be called a Dutchman. various shapes are possible, double ended dovetails are common to keep a board crack from getting bigger.
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01-22-2018, 7:39pm | #14 | |||||||
Barn Stall Owner #327
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Quote:
Thanks for the woodworking equivalent |
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03-19-2018, 8:25pm | #15 | ||||||
Barn Stall Owner #327
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The repair on the gear is complete
My friend Dave measured an original tooth on the CMM. He plotted it on the computer and Gary converted it to a .dxf file so a replacement tooth could be cut on the water jet. Bill Hazzard got the teeth and hand fitted one of them to the mating gear. A dovetail was cut in the gear and then the replacement tooth was profiled using the same dovetail cutter for a press fit. |
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03-19-2018, 8:29pm | #16 | ||||||
Barn Stall Owner #327
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The tooth was then loctited and peened in place. A little time on the lathe and a great job on saving the original gear from the 1893 17 HP Otto engine
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03-20-2018, 4:02am | #17 | ||||||
Barn Stall Owner #13
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Excellent work!
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03-20-2018, 7:32am | #18 | ||||||
Barn Stall Owner #97
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Nice job with what you have to work with!
Please do yourself a favor and upgrade that rocker post tool holder! |
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03-20-2018, 7:44am | #19 | ||||||
A Real Barner
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Beautiful work!
Just a thought; but shouldn't the tooth and stitch have a date stamp? |
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03-20-2018, 7:13pm | #20 | |||||||
Barn Stall Owner #327
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Quote:
This is Bill's lathe, a L Robbins kathe. It's run by an overhead belt and the hit & miss engine you hear in the background Here's his shop from 11 years ago |
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