Converting a TT HS worm to an AA

[John Duden]

Project ive been working on, I took a TT worm and Converted it to fit in to an AA axle. The TT is about an Inch shorter and the splines are different, The AA and the TT are identical up until the splines.
I took a low speed AA worm and cut the splines off in the bearing surface then faced it off in the lathe until it was the correct length (holding it next to the TT shaft) The outside is case hardened so it is kinda hard to cut. I drilled a hole 3 1/2 inches in the new coupler 5/8 diameter. I decided to machine the hole square so the drive on the worm would rely on the square and not the weld where it could break off.
i cut out a set of carbons on the milltronics, one rougher and a finisher and then set the part up in the EDM and cut the square in to it.
The shaft was set up in two vices and 2 Vblocks in the mill and all 4 sides were indicated and milled flat to make the 3/4 drive square. after roughing i reindicated it back into the mill and measured every side and marked every side to fit it to a side in the new coupler. gauge blocks were used and an indicator was run along it to insure every thing was milled to the right size.
After all 4 sides were finished i put the shaft in the lathe and cut a chamfer on both the shaft and the coupler so it could be welded together. And to finish it turned the weld true so the bearing can ride on it

[Tom Wesenberg]

Nice work. And here I thought you were a farmer.

That doesn't look like a farmer fix.

[John Duden]

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Originally Posted by Tom Wesenberg

Nice work. And here I thought you were a farmer.

That doesn't look like a farmer fix.

You have no idea how hard it was to be patient and get it within a 1/10 of a thousandth! Im not used to that!