This is one of four stock Martin gear and pinion sets that need to be machined to fit the Shay trucks.
 

First, I opened up the bores of the ring gears on the lathe to a certain depth because I planned on reusing the cut off hubs later when fabricating the universal joints.
 

I made a simple fixture to hold the ring gear vertically in the horizontal band saw to cut off the hub.
 

The ring gears were positioned so that the saw blade would just clear the opened up bore depth.
 

I was pleased at how straight the saw cut through the ring gears on the fixture, leaving as much of the hubs as intact as possible.
 

Back to the lathe to turn the front faces of the ring gears.
 

A ring gear positioned on the mill to drill and counterbore the mounting holes using the bolt hole circle function on the DRO.
 

The pinion gears needed to be bored out as well. These will receive a special drive hub that will be TIG welded in place.
 

Turning chamfers on the pinion gears and drive hubs for TIG welding.
 

The pinion gears and drive hubs ready for TIG welding.
 

Completed ring and pinion gears ready to be installed on the Shay trucks.
 

I fabricated two simple frame stands that bolt onto my hydraulic lift table in order to easily roll the trucks in and out while providing a stable base for the frame and engine.
 

Getting prepared to work on one of the Shay trucks.
 

Drilling and tapping the gear mounting holes employing the same DRO bolt hole circle specs used for the ring gears.
 

Broaching key ways in the wheels. One down, seven to go…
 

Cutting a key way in one of the axles.
 

Completed wheel, gear and axle set.
 

Bearing bronze thrust bushings are installed in each firemans-side truck journal behind plates with adjustment bolts to ensure there is no side-to-side axle play.
 

I also bent and added the truck frame end bars at this time.

Now on to the truck brakes and paint…