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Discussion Starter · #1 ·
Hi guys.
I have had a Skil belt sander model 595 dustless for many years. I have been searching for a piece but it looks like there are no spare parts for it anymore.
I have repaired it by myself several times but this time the small plastic gear has broken in so many pieces that it is impossible to gather them to glue using CA.
The big plastic gear is almost broken too.
I´d like to hear some advices from you to get my BS get back to work.
PS. Does anybody know how to remove the big plastic gear?
 

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Theo
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I'm thinking a machinist could make one, but it would likely cost, a lot. lf I had that problem I think I might make a master out of wood (separate pieces, then glued together), then try casting one out of plastic, or aluminum or brass. Hmm, just struck me, I'm almost willing to bet that there are gears out there, being used in different tools, in just the sizes you need - but I have not a clue where to start looking. Sorry, best I can come up with.
 

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I would vote with Theo and Herb and try to find a pair of gears that have matching tooth profiles.

Based on the puller indent on the shaft I would bet the big gear is pressed on...

Check the hub of the gear to see if there's a set screw going through the hub to the shaft...

The only other possibility is that it is screwed on in the same direction of the motor spin but I don't think so...I'm betting on pressed on...
 

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I would vote with Theo and Herb and try to find a pair of gears that have matching tooth profiles.

Based on the puller indent on the shaft I would bet the big gear is pressed on...

Check the hub of the gear to see if there's a set screw going through the hub to the shaft...

The only other possibility is that it is screwed on in the same direction of the motor spin but I don't think so...I'm betting on pressed on...
The big gear looks like it is off center,....MMMMM I bet it will break if removed, already has cracks in the hub.
Herb
 

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The big gear looks like it is off center,....MMMMM I bet it will break if removed, already has cracks in the hub.
Herb

More than likely...but there's an inner hub against the shaft...even if it breaks finding two new gears is still needed...
 
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Theo
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Herb's post gave me an idea, so did a search for Skil belt sander model 595 dustless replacement pullies. First post was offering a front roller on ebay. So looks like that search might come thru for you. I didn't check anything out, just wanted to pass it along.

Also made me think that perhaps you could get along with different size pullies, perhaps even chain drive (not so sure about a chain whizzing around).
 

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Alexis I'm wondering if the big gear comes off the shaft after you remove that shaft from the machine. In other words, off going the other direction. Theo's idea of casting something has merit. Maybe you can glue it back together well enough to make a mold. What you would have available to you to do that is the question.
 
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Remember, Alexis is in Venezuela.
It may well be easier and cheaper to just buy a new or reconditioned belt sander from the US and try and find a safe method of shipping (getting ripped off is the norm from my latest understanding).
Thanks for mentioning that, he changed his Avatar, and I didn't recognize him. Yes that might be a problem and your solution might be best.
Herb

In his Bio "Now I am living in China. My home is Puerto la cruz city, state of Anzoategui, Venezuela"
 

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Discussion Starter · #14 ·
Hi guys.
Thank you for all your input.
This is my oldest BS. I bought it along with a Skil router in Mentor, Ohio by early 90s for ten bucks. I love it because It is a heavy duty tool.
I contacted Skil´s Customer Service center and, surprisingly somebody fron Bosch answered me. They asked for the model number which I gave to them but, It does not follow the code model rules used now a days.
I visited two metal milling workshop looking for a solution. One rejected the job because it is a time consuming activity. The other was asking for a huge price. Both of them are working to closed doors due to the quarantine.
Herb´s proposal sparked an idea to look these gears for at home appliances workshops.
The big gear seems to be threaded but I have tryed to remove it by moving it CW and CCW without succes.
 

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I just looked on eBay and while your model wasn't found exactly there are many vintage Skil sanders for sale for almost nothing to expensive. Find the part number and check for it in other models and search eBay for it. I once found an obscure nylon gear for an antique pencil sharpener that way. In the process I found a fellow that made them as I guess there was a market for it. So do some clever searches.
Bill
 

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