My tiny repair

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A gearbox shaft with a pressed on gear broke in a Halloween animitronic.. thing..They gave it to my mom because it was broken. Took it apart, a shaft snapped at the E-clip shoulder. Looked like pot metal, was barely magnetic!..1/4" bar stockGear was about 0.075" thick3/32 Ceriated105A Pulsed, 65% pulse time, 50% background, 5 PPSI believe I used 309SS 3/32" because I wasn't sure what type of metal the gear was.. but it was crappy!I used my magdrill to spin it, poo man's positioner!Last edited by JohnR; 09-09-2011 at 10:08 PM.Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:Forgot to add, the second pic is just to show you the jig for making sure it was flat before I welded. I knocked the socket off and ran the end of the shaft flat (hard) against the 1x3 for ground so I wouldn't kill my bearings.Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:No one ever likes my work Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:nice job!_______________________OF COURSE I DON'T LOOK BUSY... I DID IT RIGHT THE FIRST TIME
Reply:Good job on the repair and great idea on using your drill on the positioning  of the shaft.
Reply:When you said Tiny, you weren't joking.  Nice work.Qualified & experienced at welding scrap metal
Reply:Forgot to add.It was a bit tweaked after welding. It was still perfectly flat along the gear edge, but was lifted up on the edges (think cymbal). I tacked a dog to the table, and used some scrap tacked to the dog to pressure the edge back to flat using the socket as the stop. I think it's straighter now, than it ever was before! I put it all back together and it spins very well with NO gear noise (which couldn't be said for the original!). I think I lucked out.. the OD of the gear was too small to properly mesh in the gearbox before I spun it back to full size..Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:Originally Posted by JohnRI used my magdrill to spin it, poo man's positioner!
Reply:using tools in a manner that was not originally intended. gotta appreciate inginuity.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger