Hi All. I am currently about to start building my 3rd kx250 in the space of about 2 years. Anyway I have run into an issue where the gearbox drive dogs appear to have rounded edges on them causing the gears to pop into neutral. 3rd gear if my memory corrects me. Now I have two sets of full gearboxs all with the same kind of wear and im not that interested in trying to buy another 2nd hand unit as well most of them that I have seen on ebay have the same type of wear on them anyway. SO it dawns on me I have access to a lathe and a mill with a rotary table and I plan on re cutting my drive dogs. Has anybody done this process before? I know I will have to heat the gears cherry red and let cool down slowly to soften the hardness to perform the milling. But how would I get the gear back to the correct hardness after I have heated the gear cherry red and dunked it in oil? this is a process I can say I have only done once when I was back in school so im keen for your input.
Also since I am going to all this effort I have thought about undercutting the drive dogs and matching them. If I do go down the route what angle should I cut the gear at? I havnt been able to find much information about this process and to be honest I cant afford to pay someone to do this work as my house renovations are getting out of hand. (gotta be able to keep the kx dry afterall)....
Here is the only video I have found online that is of any relevance to what I want to accomplish but I am keen to hear your input
https://www.youtube.com/watch?v=2gFXvgSsAJcAnd here is a photo of the first kx I built.
