The last two days have been a bit of a milestone in my gear cutting journey as I have managed to cut the missing gears for my two Shogun gearboxes.

I initially test fitted them and ran the motors with the gear rotating on the axle as I didn’t have any small enough grub screws and was pleasantly surprised when they ran freely. Next, I made some tiny grub screws from some lengths of 10ba stud that I had cut off some one inch, 10ba screws. I keep all such things in a plastic Ferrero Roche box as they do come in from time to time. I was trying to be a bit clever by using a very small slitting saw in the Proxxon pillar drill to cut the slot but the blades that I have, are too thick and it ate away half the thickness of the screw. So I cut the slots by hand with a piercing saw.

After chasing them around the workshop floor and miraculously finding them after dropping one grub twice and the other once, I fitted the first one. It all worked as intended and runs as smooth as the other gears. However when I tried the second one it was a bit lumpy and then I noticed that although it seemed to fit okay between the frames it had splayed them slightly so I popped it back in the lathe and skimmed both ends slightly and on the next try it ran just like the first one. Now I really am a happy bunny.

Just for scale this is one of the gears again a 5p piece. They are very small.

Once again, I would like to sincerely thank all who have contributed to my getting this far.

From identifying the gearboxes that I bought at Stafford, to working out via information provided by fellow members that it was a 29 tooth Mod 0.3 gear that I needed to buy or make and all the helpful advice on both the theory and practical aspects of gear cutting. It really is much appreciated.