Fine downfeed phase1: Cutting the worm gear blank

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I needed a quick gear blank, so I grabbed a hole saw that I had laying around and cut one from a piece of 1/2" aluminum plate. It took a while for the old dull saw to cut through, but it was the quickest way I could think of to make the blank.

 

 

After cutting the blank, I bored the center hole and trued up the blank on my little Harbor Freight lathe.

 

The blank wouldn't fit in the jaws of the chuck, so I had to bolt the blank directly to the face plate