Emco Super 11 Change gears, gearcutting and threading 

nice work but they leave some pitches out of the gearboxes so every now and again you can skip the job and relax. you're not supposed to make your own change gears. those charts are made up. you got really lucky.

I have received a mini heart attack at 5:26 I haven’t seen the small piece of paper and thought: "OH GOD NO! he`s drawing in the Tabellenbuch!!!" Perfect addition to the Sunday afternoon coffee! Your videos should be shown in vocational school! Unfortunately with this beautiful gear set, my last hopes are gone that you change your mind and mount an ELS III to your EMCO. Great video!

@32:42 Stefan realized how convenient it is to have a D-bit grinder in the workshop. Saved his bacon :-D

Great video Stefan, thank you. Also, as someone born with a genetic lung condition and having a 27% lung capacity at 30 years old I agree, looking out for your lungs is very important. Minimising exposure to dust is essential, you don't want to be in my position, trust me.

A little Bakelite with my coffee this morning. Chevrolet used it for silent timing gear in their "Blue Flame" six for decades, and yes there may be just a smidgen of asbestos for added flavor. Got to love it when Stefan makes 40 parts for a 1/4 in of thread in under 35 minutes.

@32:43 Stefan "I might need a little relief on that tool!" Do remember the dust when cutting old phenolic circuit board years back. Lovely smell too!

Even if though I am not a machinist I really appreciate your videos, and your attention to detail. There is something to learn from your approach to problem solving. Thanks for sharing!

Phenolic, is an excellent material, both Linen and Paper impregnated version, "Tufnol" is the most known brand name here in the UK, "Carp" and "Whale" are their product name, but an absolute mess to machine, as you can see. We use if as a non marking clamp on chromed rod. Always a pleasure, and education to watch Stefan. Thanks for sharing and best regards from the UK.

Thanks Stefan, very interesting. I believe I've seen phenolic gears before in devices. 👍. Beautiful work as always.

Had to smile when I saw this because recently I had to make a bunch of 14.5 x 0.75 male & female threaded parts for Primus burners. Fortunately my Emso Maximat 11 came with the accessory gear set for the non-standard pitches so I didn't have to make the gears first. But - I've certainly had to in the past, with other lathes, for oddball pitches. Anyway, nice job. Those Emco lathes are beautifully built, I don't ever plan on parting with mine. One day I'll fit a DRO though.

you can prevent "tear out" on micarta by backing it up with pretty much anything. Most of the time I have used another piece of micarta, but alum at least .040 works quite well.

33:20 "That's a nice .75mm thread". It is - it's perfect and I'm glad to hear you say so. Not "That's pretty good" or "That's OK" or some such. Not only the thread, but the video - thank you.

With the care you take, the gears you made will last a long time. Phenolic gears are use in many commercial gear boxes. Great job !

@Stefan, you're a real role model. As an unqualified CNC machinist in South Africa, very few people here can help me with the finer detail of the trade. You answer all my wildest questions and give me so much advice and tips. Thank you for that.

Stefan....your video production quality, discussion, demonstration, build....IS EXCELLENT.....lots of lessons within the video...thank you for your craftsmanship and sharing your TIME

Brought back memories making a 127 Z phenolic change gear some 30 years ago for my Australian Hercus Lathe using compound indexing head. Excellent info regarding the layer construction of Phenolic round verses sheet strength.

Ah, the classic few seconds of blank footage where an unseen large hammer comes out to remove stuck change gears.

endlich wieder Späne und gepflegte Maschinen-Unterhaltung 😁

Great job. I have the same lathe which I purchased more than 30 years ago. Great lathe!

Great job on your project and description. The use of such a transmission affords many different resultant ratios - and thread pitches.

It was great watching you work. Thanks for the video.

Stefan, I cut a lot of gears and splines over the years in my old job I retired from (automotive engine and drivetrain) for replacement parts in components. These were cut primarily with gear bobbing and shaper equipment. A lot of the gears were Fellows Stub Tooth in which they used the the pitch diameter of one size and tooth height of the next smaller pitch. This would be expressed as 10/12, 8/10, 12/14 etc. What I'm getting at is is there a Module Stub Toothed for

24:50 "very entertaining situation" had me rolling

Hi Stefan, very nice video, especially if you only have to look at the first 3 teeth and the last one. I have an Emco Maximat V10 lathe with the vertical milling column. It was my fathers machine that I inherited when I was 18. I am 55 now and my shop is too small so it is stored in a wooden box and I bought a "bernard" Chinese lathe that is much smaller and without a gearbox (you only do it by swapping gears which is a pain in the neck). Your video recalls the times when I made m=1 gears and the stress of doing all the repetitive work fearing not to end up with a tooth overlap. At the end of those tasks I always wanted to automate the rotary table brake and rotation at least. I am following your channel for a couple of years (excellent content) and guessed your height might be close to 170. I had to get myself into the mood to see NY CNS's video about your shop (due to its length) and was surprised that you are 203. At the end it was a very enjoyable video. I would not like to get with you on an argument about who is the next one to use a machine at your job.

Harry from Texas USA you are a Wizard Machinist I enjoy your many jobs fantastic work 👌

Just thread 1.75mm right handed, then 1mm in reverse left handed. I swear it works!

I was watching you putting that 95 Toothed gear on and wondering how long it was going to take you to realize you needed a smaller spacer gear behind it... The anticipation near killed me!

Found your channel and subscribed through This Old Tony and so far am very impressed. I use that same material and also something called Garolite (may be a trade name) that I purchase through MSC here in the states. Use it for a lot of different things. It is also heat resistant and an excellent insulator. I build fixtures for induction braze machines so these qualities are much needed. It is rough on cutters. The material is so dense that heat stays at the surface being cut which will break down a cutting edge quickly. I use only carbide and your use of the shop vac is also correct. It is nasty stuff and the dust gets everywhere. Great job.......

You need that electronic leadscrew kit from Clough42!

32:41 to 32:43... ninja grind on your thread cutting tool :D

Anyone notice the drive belt on the Emco Super 11 is a flat belt? Stepan I don't know where you learned English but is very good. Thanks for sharing. Your videos area always well done and interesting. I also appreciated your hands. They are working hands. Someone that has been there done that and has the scars. :)

The 95 tooth gear is there only to transmit the rotation and bridge the gap, it has no effect in the reduction ratio. Any gear that fitted in the available space would do and probably saved you some work. Not as fun or fast, but you can also order very cheap 10mm thick mod 1 gears in steel from the popular auction site (the 40 teeth is going for less than 5€ with postage). I've done it before because my (used) lathe was missing the change gears, only had to bore them and add the key.

Those gears will last forever. The Emco 7,8, and 10 used phenolic gears in the head. They only went bad when you tried to shift speeds before stopping. You could retire making gears for those as they are now made from unobtainium and many ham fisted gear grinders had those smaller lathes. Great video, thanks!

Love watching your videos Stefan. Very informative and your a very good demonstrator. Learning from someone with your knowledge is awesome. Thanks again.

Your a true Craftsman, your very good at what you do. It is sure a pleasure to watch your video's, I sit here watching like ET and sucking it all in.

"WARP 9 Mr. Stef!!!"

Years ago I did phonic gears. There were quite common in old textile machines, here in the states. I machining a lot of Delrin or UHMW for projects, out of sheet using a similar method.

And that's how its done boys and girls. Thanks Stefan for the lesson, and a pleasant video. btw Is phenolic better in this application then say aluminum.

Very fun to watch you work. I learn a lot just seeing how you approach things. Middle Illinois.

Thanks for sharing Stefan, I always learn something new when I watch these videos.

Fantastic as always! Interesting material..

Very nice! I've noticed that even with dust collection after a long job working on phenolic I'll have sinus problems for a day or two.

Most entertaining and educational. Funny how the threading tool suddenly got a notch on the left side between two threading passes at 32:34

Very nice. I have an EMCO 5, which has change gears only and only the metric gear set. For imperial, it uses some approximation for the 127/50, there was an imperial gear set from EMCO which I didn't have. I 3D printed the gears per EMCO table in PLA, these gears have been working fine for 2 years now. It's a much smaller lathe though.

love the little adjustment to the threading tool . :)

Great video Stefan, I always enjoy watching your skill and expertise....

Absolute perfection from start to finish, thank you for sharing.

"I'm very pleased" means it's better than most of us could hope to do.

Nice job Stefan. Thanks for taking the time to show that. Good video.

Took my brain at least 2 minutes to catch up when he said "I don't have a thread pitch gauge so I'm using a nut" then he produces a thread pitch gauge like 10 seconds later. The first statement, I believe you meant a Go, No-go gauge (or something similar). If not, well I'm still confused.. hehe Love yur content Stefan, keep up the great work.

G’day Stefan, nicely done as always. Cheers, Peter

You're the man Stefan!!!

Great stuff IMHO I serviced and ran 16 Kinoton projectors that all used various sizes of phenolic gears as large as several inches in Dia.. I would sure use it like you did. Seemed to me they "wore" much better than metal would have.

Great video 👍 I got the manual you were talking about in previous videos it was written in German 😂 but I still use it at times. I always like the way you make things come to life 🙂:-)

Clough 42 is developing a electronic digital gearbox for his lathe. The development is near completion and has generated quiet a bit of interest among his RU-vid viewers. It's very interesting and worth checking out.

Hey Stephan, I feel your change gear pain. My Hardinge has a 33.3 DP with a 20deg contact angle if you can believe it. Which means there’s absolutely no involute gear cutters in existence to make the 127T I am missing to be able to do metric with an inch gearbox. So I’m stuck with single point hand grind or getting fancy with the material choice on my 3d printer.

The chinese mini lathe use much the same change gear set up. Thanks. As always fine work.

I had a 1955 Holden ( made in Australia), GM Chevrolet design. The timing gear on the camshaft was made of phenolic linen matrix. They lasted about 15,000 km (10,000 miles) before they broke. Usually on a Saturday morning, when you needed the car to take the girlfriend out in the evening. Those were the days, my friend................. Stavros

Great video. You make it look so easy. Thank you.

Excellent work again Stefan. I am wondering what formula you use for setting the tooth depth? Regards , Mark Presling

25:30 What's with the blackout❓ 27:30 Why not use a strip of paper between the gears to help with the spacing❓ 29:05 Saw that coming!

Some people have way too much fun!

As we might say to @joyofprecision, you went "Full Watchmaker" on the extra change gear bolt! Beautiful work Stefan. And... I might add... Nice & quiet!

Very nice Stefan! Thank you! I will apply this to my super 11 lathe .

You gotta be doing an egress part ! I’ll wait for your announcement.🕰

You have it covered, Stephan. No further comment. 👍

Great information regarding the phenolic material. I think I would have started with the round type and found out the hard way. As mediocre as my Chinese lathe is, it came with change gears for the two pitches I cut most. Those are .75mm and 11-1/2 TPI.

Well done Stefan! Knowledge is law. Cheers

always amazing with a tad of humor

Enjoyed it Stefan! Thanks for sharing.

Damn I like that Walhaupter.

I'm surprised you didn't use your Electronic Positioner on your rotary table.

I'm a little disappointed Stefan. I mean you didn't pantograph the number of teeth into the gear and when that sharpie wears off and you're old you're gonna have to count them😂 just kidding👍

Perspex/acrylic 12mm sheet also good for gears like this..

Thank you Stefan.

A very nice and interesting vídeo. Congratulations from Brazil. Eng. Nilton Polydoro

This is odd! I have the imperial version of this lathe, and I can cut metric 0.75 with the gears provided (8 to the inch leadscrew, use 120/127 gear pack in headstock side). I can also cut 1, 2, 1.5, 0.6, and 0.5. On my lathe, gearbox ratios (on the 1-2-3-4-5 lever) are 24/16, 24/14, 24/12, 24/10, 24/9 (to give 16,14,12,10,9 threads/inch) with A-B-C lever in C position. B and A position halve the ratio, giving imperial threads double and quadruple those in the above list. All of this is with 30T gear on spindle and 90T gear on the gearbox.

I have to make some gears for my mini lathe seeing this levees me no excuse now!!

Nice video Stefan. I like the grind for clearance on your threading cutter. I had to do a double check. wasn't that a perfect point a few seconds ago? Yep!

Stefan, you are the most meticulous de-burrer around, but I guess that is the only way to make the nicest parts, cheers!

Very nice... thank you for sharing!

Any idea how straight that lathe is? I know even the smaller Emco lathes were built to a very high standard.

Well done! Thanks for the video. 👍

Why did you need the 95t gear here? It doesn't seem to actually be participating in the ratio, so couldn't you have just used the 120t or 127t gears instead? Just trying to complete your set of gears for the Emco?

Well done as always! I'm hunting for an Emco Drehmaschine on Ebay Kleinenzeigen for a while, hope I can get model 10 in a good shape :)

Thanks Stefan !

I think your dust extractor works very good. But just to be sure, can't you come over here and test it in my living room?

What a lovely video. Ausgezeichnet!

Excellent work!

You make it look easy!

I always wonder how the number of teeth of "intermediate gears" (like the 95-tooth gear here) is chosen, because it doesn't really affect the gear ratio, and yet someone didn't specify a 100-tooth gear, or "any gear that fits", but a 95-tooth gear specifically... or maybe put differently: why didn't you just reuse e.g. the 120-tooth gear instead of making the 95-toothed one?

It's best to use carbide or CCBN/PCD when milling or drilling in Micarta due to it being highly abrasive. Biax! Did you buy that new?

nice gears and great machining

Nice job , i see you had to relieve the tool mid way . Cheers .

At 34:33 how did you get that divot in that shaft using the lathe? 😮

Reminds me of Uri Tuchman's preserved lemons. ;)

Nicely done!

Thanks for sharing. I'd be interested to see how Vesconite holds up

Very nice! Wish I could afford to upgrade from my Chinese mini lathe, but I might think about fitting some extra gears...

Standard gear mesh settings: “Touches but doesn’t bind.” ;-)