How do I index?

Messy? You should see my shop :)

Looks like your setup is OK. I would have the stylus more vertical, but what you show should work, I can't imagine being able to put enough torque on the spindle to rotate it with that setup.

So the process is to make contact with the part, move the x axis to check the alignment, rotate the rotary table a bit, check again, rinse-repeat until the work surface is aligned with the x axis (zero movement on the DTI dial)
 
so once I indicate 1 face, 72 degrees will line me up perfect and I wont have to indicate the other faces or should I still check? So, I should set the head to 0 first obviously......
 
Yes. 5 divisions of a circle, 360/5 = 72
However do not expect OEM parts to be as accurate as you think they are or should be, it is likely that the OEM finished surfaces are far harder then you anticipate as well.
 
I know its probably not super accurate but I want to stay close. Yes, its a hardened gear and looks like it was probably shot peened aswell. I have the appropriate cutter for it. carbide with ATLIN coating? and going to take light passes at 2700-3000RPM as people have suggested. Its a small bit... 1/4"? with 3/8" shank.
 
Good luck with the machine pictured using carbide tooling.
If you do not mind my asking what does a new OEM gear cost?
 
Instead of indicating on the wall of the gear, indicate on the teeth--these are the only real reference surfaces you have.

Face of a tooth--vertically.
 
Mitch Alsup said:
Instead of indicating on the wall of the gear, indicate on the teeth--these are the only real reference surfaces you have.

Face of a tooth--vertically.
Click to expand...
what is that going to do when i am making a horizontal cut? I am cutting those 5 dogs in the center of the gear, they are not lined up with any one tooth.
 
P. Waller said:
Good luck with the machine pictured using carbide tooling.
If you do not mind my asking what does a new OEM gear cost?
Click to expand...
i have talked to alot of machinist that have used these mills, they are not bad...... obviously not making satellite parts with it but for what im doing it should be fine. new gear is about $70...... but they are discontinued and that still doesnt prevent future issues. To have this done by a shop that does this as a standard service is about $500. If I fail at it, oh well... atleast I tried.
 
I reindicated the gear. looks good but cant cut because my 3/8 collet appears to be stripped and I cant re-tap it. tried but no way to hold the collet without damaging it and its so tight that I may end up busting a tap in it. will order a new one. any suggestions on where to get one? Im always hesitant of ebay china crap. maybe I get lucky and find a Bridgeport collet.
 
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