Fly Cutter

Project:
Creating a fly cutter to cut a 39 tooth gear

Difficulty Level (Easy, Medium, Hard, Insane):
Easy

Process:
This one was actually quite easy. So easy in fact that I hardly took any pictures. I simply took a piece of 1-1/4" cold rolled steel, turned the shank down to 3/8", milled a slot at the bottom for the high speed steel tool bit, drilled and tapped two holes for the set screws and that was pretty much it.

Pictures:

Tapping the holes for the set screws

Close-up of the tapping action

The fly cutter in action on a piece of nylon

The finished 39 tooth gear

Tools:
Lathe & accessories
Tap & die set

Materials:
3" of 1-1/4" cold rolled steel
2 set screws

Cost:
$0.00

Time:
2hrs

Savings:
$30

Conclusion:
It works great