How would you make this internal gear?

[Jubil]

I may be confused. Which gear Id are you wanting to duplicate? Left or right?
Chuck

 

[mksj]

You might also check with a few places that specialize in making gears, a few examples below. You would probably want to heat treat the gear.

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[solo]

I may be confused. Which gear Id are you wanting to duplicate? Left or right?
Chuck

The I. d. of the gear on the left

 

[Lo-Fi]

Make up a push broach from tool steel. Cutting the outside profile shouldn't be too difficult and certainly far easier than shaping the inside splines directly.

In fact, I think you can cheat with the smaller diameter and not even have to cut that into the broach. I'll knock up a CAD doodle if you like? They're parallel, straight flank splines, so dead simple.

 

[Jubil]

The I. d. of the gear on the left

Sounds like you would prefer to make this gear yourself,(the whole idea behind being a Hobby Machinist). I don’t have a good idea how to index the broach or other way of cutting those splines. But I’m sure you can buy spline sleeves, or couplings from most industrial suppliers, then fit a ring gear to the outside.
Chuck

 

[solo]

We have a 18" Cincinnati Tray top with a few bad gears.
I need to duplicate the I.D. like the gear on the left beside it. I have some bronze I'm going to use.
I have a broach, but how to index it correctly? I was thinking of making a key and attaching it to the side of
the broach guide. How would you do this? This is at work! A want to be machine shop. I have limited machines and tooling to work with. My equipment at home is better. Mine is new, or near new.

 

[OTmachine]

Fab a shouldered broach guide bushing with 6 equally spaced slots for the broach. After you broach the first slot, install a custom fit key to locate the bushing on that slot. Then broach the rest of the slots.

 

[solo]

I think I'll go with what Welding rod 1 said. It seems the simplest. Thanks all.

 

[brino]

I think I'll go with what Welding rod 1 said. It seems the simplest. Thanks all.

Please share your results!
Thanks,
Brian

 

[solo]

It's almost finished,of course the setup took the longest. I missed the mark grinding My tool bit, went .006 undersized. I'll take care of that tomorrow and start reassembly. Fun days ahead.