Making the Auger Motor and Gear Box Parts

This page describes how you might make the parts for the Auger Motor and Gear Box. Keep in mind that there are probably many other methods that will work. Choose a method that works for you. If a particular part requires an expensive tool you don't have, consider having a friend or local machine shop do it for you. If you have any recomendations, tips or questions, please don't hesitate to contact us. - Thanks

Making the Bottom Plate

Drawings

Tools

Item No.	Image	Name
1		Drill Press
2		Drill Press Vise
3		Drill Bit - 1-2 in
4		Reamer 3-4 in
5		Drill bit 13-64 in
6		Hacksaw
7		Scriber
8		Center Punch
9		File - Flat
10		Pipe - short piece
11		Digital Calipers
12		Countersink bit
13		Tap 1//4 in 20 tpi

Process

Step 1: Lay out and cut the metal plate to the correct dimensions. Make sure that the edges are square. It is easiest to do this by starting with a piece of 1/4 x 5 in flat bar and cutting to length with a horizontal band saw. A hack saw will work though the cuts will need to be cleaned up with a file.

Step 2: Select two adjacent edges as your references and layout the centers of all holes according to the drawing using the digital calipers and combination square.

Step 3: Center punch the location of each of the holes.

Step 4: Drill the four 1/2 in holes to size. Begin with a small pilot hole. If your drill press isn't too strong, You may need to use a number of smaller bits to work your way up to 1/2 in.

Step 5 Drill the four holes that will be tapped using a 13/64 in drill bit. NOTE - if 1/4 inch fasteners or taps are unavailable use a 6mm tap instead and size the pilot hole accordingly.

Step 6: Tap the holes with a 1/4-20 tap. Starting to cut the threads by chucking the tap into drill press and cranking by hand will help to ensure that the threads are perpendicular to the plate.

Step 7: Drill a small pilot hole where the 3/4 hole will be then step drill your way up to a size just under 3/4 in (23/32 in).

Step 8: Ream the hole to 3/4 in. Reaming produces a more precisely sized hole than drilling and should provide a nice press fit for the bushing. If you can't find a reamer, you could try drilling the hole or boring it on a lathe.

Step 9: Remove the burs from the edges with a flat file and from the holes with a counter sink bit.

Making the Top Plate

Drawings

Tools

Item No.	Image	Name
1		Drill Press
2		Drill Press Vise
3		Center Punch
4		Combination Square
5		File - Flat
6		Hacksaw
7		Scriber
8		Vise
9		Drill Bit - 1-2 in
10		Drill Bit 5-16 in
11		Cold Chisel
12		Digital Calipers
13		Countersink bit

Process

Step 1: Lay out and cut the metal plate to the correct dimensions. Make sure that the edges are square. It is easiest to do this by starting with a piece of 1/4 x 5 in flat bar and cutting to length with a horizontal band saw. A hack saw will work though the cuts will need to be cleaned up with a file.

Step 2: Select two adjacent edges as your references and layout the centers of all holes, including the holes located at the corners of the cutout and at the end of the slots, according to the drawing using the digital calipers and combination square. If you are not using a mill to make the slots and cutouts, make sure to scribe a line connecting the centers of the holes at the ends of the slots and corners of the cutout.

Step 3: Center punch the location of each of the holes. Also center punch a series of holes along each slot and edge of each cut out.

Step 4: Drill the four 1/2 in holes to size. Begin with a small pilot hole. If your drill press isn't too strong, You may need to use a number of smaller bits to work your way up to 1/2 in.

Step 5 Drill the holes at the ends of the slots and at the corners of the cutout. Also drill a series of holes between the ends or corners.

Step 6: Using a cold chisel, remove the cutout and open up the slots.

Step 7 Clean up the slots and cut out with a flat file.

Step 8: Drill a small pilot hole where the 3/4 hole will be then step drill your way up to a size just under 3/4 in (23/32 in).

Step 9: Ream the hole to 3/4 in. Reaming produces a more precisely sized hole than drilling and should provide a nice press fit for the bushing. If you can't find a reamer, you could try drilling the hole or boring it on a lathe.

Step 10: Remove the burs from the edges with a flat file and from the holes with a counter sink bit.

Making the Auger Gear Shaft

Drawings

Tools

Item No.	Image	Name
1		Metal Lathe
2		Hacksaw
3		Combination Square
4		Scriber
5		Digital Calipers

Process

Step 1: Cut a piece of hexagonal bar a bit longer than shown in the drawing.

Step 2: Using a lathe, face each end and then turn the shaft as shown in the drawings. Make sure that the fit between the shaft and the bushings isn't too sloppy.

Step 3: Using a flat file, make the square drive in the end of the shaft. NOTE: Easier or more accurate results may come from doing this on a milling machine with a dividing head or rotary table. Using a file will work fine though. Take your time to make sure the drive is centered.

Making the Auger Gear Support Disk

Drawings

Tools

Item No.	Image	Name

Process

Step 1: Center punch the center of the disk and use a divider to mark the edge of the circle.

Step 2: Cut out the disk and clean the edges with a file so that it fits the gear.

Step 3: Use the printed part to transfer the hole locations to the disk. Drilling through the holes in the disk works. A transfer punch will also work well. Just make sure that the disk doesn't shift while marking the holes. Also mark the edges of the hexagon using a scribe.

Step 4: Drill the holes. Drill the center hole out to 3/4 in. If you don't have a 3/4 in drill bit (or step drill) you can just use a 1/2 in. bit but you will need to do more filing in the end.

Step 5: Bolt the disk onto the printed gear and then use a flat file or square file to file the center hole to match the hexagon in the printed part.