I’ve turned both the OD and the step and now I’m breaking the edges. I’ll put a slightly larger break on the backside to make sure and clear any corner radius on the cam ring where this seats. Make sure the OD will be a slight press-fit to a tight slip-fit in your cam ring.
Moving over to the mill, I’ve cut a circular pocket in a set of aluminum soft jaws. I clamped on a 3/4″ wide parallel while cutting the pocket to 2.502″ diameter. Make sure and set your zeros or record your center position for the pocket.
At this point, I’ve got the cam gear sitting in the recess in the jaws and the jaws closed down to where the cam gear can just rotate. With X still centered, I’ve chucked up a center and have moved Y up to position the center in a tooth root, and then tightened the vise.
The previous step resulted in having a tooth root aligned with the Y axis, but I want to put my roll pin holes aligned with a tooth so I need to rotate my holes by 360/48/2° which gives me cartesian coordinates of X = 0.0784″ and a Y = 1.1959″ for my two holes.
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