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Brass Synchro Cone Ring: Turned with a Taper Matched to Its Seat
In a synchromesh gearbox a cone-shaped brass ring on the gear is pressed against a cone on the sliding collar, and friction brings the two to the same speed before the teeth engage (Wikipedia, Manual transmission). Factory rings are forged or pressed from brass or steel; this one is turned from brass bar, with its cone and the seat it runs on cut at one lathe setting so the tapers match. Method and sizes are ours.
The picture: our drawing.
Intermediate
Half a day
Instructions
1
1
Face, drill and turn
Face, drill and turn
Chuck the brass bar, face it, centre-drill and drill through, then turn the outside to the ring's diameter.
Materials for this step:
Brass Rod1 pieceTools needed:
Metal Lathe
Lathe Chuck 3-Jaw
Lathe Cutting Tool
Center Drill Set
Drill Bit Set
Cutting Oil
Digital Caliper 6-Inch
Safety Glasses2
2
Bore the cone
Bore the cone
Set the compound slide to a shallow angle and bore the inside to a cone with the boring bar. Do not touch the compound setting again.
Tools needed:
Metal Lathe
Boring BarCutting OilSafety Glasses3
3
Turn the seat to match
Turn the seat to match
At the same compound setting, turn the matching outside cone on the gear's hub or collar, taking light cuts until the ring sits on it with its face just short of the shoulder.
Tools needed:
Metal LatheLathe Cutting ToolDigital Caliper 6-Inch4
4
Part off and bed in
Part off and bed in
Part the ring off, file off the burr, and lap ring and seat together lightly so they bear all round. Clean off every trace of compound.
Tools needed:
Parting Tool
File Set
Lapping CompoundTools Required
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