How to make gears

How to make gears

This video is about making gears
like the ones I use in my
screw advance box joint jig. But I used exactly the
same kind of gears for my
wooden router lift also. Normally to have gears go
at a right angle to each other you need bevel gears. But these gears are just flat gears and surprisingly they work
fairly well going at a right angle. You’ll need to create
some sort of paper
template for your gears. You can create a paper
template for the gears using my
online gear template generator. Or you can create the
gear templates using my
much more sophisticated down loadable gear
template generator program. Or if you’re using my
screw advance box joint jig
version 2 plans You can just go into the plans.
Click where it says templates. Scroll down to the
right size gear that you want. Click on that.
And then just print that out. The next step is to
cut out the template
that you just printed and glue it onto a
piece of plywood. You don’t need to use a lot of glue, in
fact the less glue you use the better. Next we cut out the
approximate shape of the circle
around the gear template. Now we use an awl
to punch a hole in the
center of the template. As well as a hole between
each pair of teeth
that are on the gear. Those holes help to
guide the drive point of the
5/16 inch brad point drill that we use to drill a hole
around every pair of
teeth around the gear. The next thing to do is
to set the table of your handsaw
to about a 5 degree angle. This gives the gear teeth
a slight bevel, which makes
them run much smoother. You don’t stricly have to do that but the gears run
a lot easier if you do. A really useful thing to do
is to add a piece of wood
or plywood or whatever and mount that so that
your blade is actually running
against it a little bit. That will cut down the
amount of tear-out
that you’re gonna get on the bottom
of your gear as you
cut them out. With the handsaw table
tilted to the right we can now cut out
the left side of every tooth. That way the teeth
will actually get
a little bit narrow as they get
towards the bottom. Next we need to
tilt the handsaw table
to the left. Now on a lot of handsaws
including mine the table
doesn’t actually
tilt to the left. So what I’m doing is
I’m putting a piece of wood underneath the piece
of plywood that I’ve got
on top of the table. Which will give me
about a 5 degree left tilt. So now with the table
tilted left. I can cut out the other
half of the teeth. Now with the holes
that I drilled earlier I don’t actually have to
fiddle around with cleaning up
the bottom of the teeth because the hole
has already taken care
of that cut. And with the table
set back straight I’m just gonna give
every tooth a bit of a trim because I wasn’t
as careful when I cut out
the initial circle. Thanks to having a piece
of plywood right up
against the blade My gear has hardly
any tear-out
on the bottom. Now we’re done with
the paper template. But before we get rid of it
let’s drill a hole
in the middle. Next I get rid
of the template by just sanding it off
on the belt sander. That’s a bit messy though
because it actually kind of comes off
in chunks so you
might want to just scrape it off
with a chisel. All right, so let’s mount
that new gear on the box joint jig and
see how it works. Sometimes they
jam a little bit. But with this one
I got a little lucky
and there is really no interference
at all. If the gears end up
binding a little bit then you can
tweak them
by just kind of filing down the shape
of the teeth a little bit. This gear
really didn’t need
any of that but just showing to demonstrate. You could also see how
the teeth are a little bit narrow
towards the camera. This is from
when I tilted the table
on the handsaw. The next thing to do
is to add a little block for where I’m gonna put
the handle on it. This gives the screw
that I’m gonna use to
mount the handle a little bit of
reinforcement. One of the things that
I always do with my gears is to add a good coat of varnish. The makes the gears
slip a little bit easier
on the jig and more importantly the varnish helps to
bind the fibers
of the teeth together so that, hopefully
that should cut down
on wear. Not that I’ve ever
had any issues with wear but just to be
on the safe side. For the handle
I just use a piece of
5/8th inch dowel with a hole drilled through it.
I use a screw
with a smooth shank. But to get
the smooth shank
on the screw it ends up
being a screw
that’s too long. But that’s no problem.
I can just cut that off
with an angle grinder. And grind a slight point
back onto that screw. I’m drilling a hole in the gear that’s just a little bit
too small for that
kind of screw so I’m gonna get
a really tight fit. And now to mount
the knob on the gear. I put the screw all the way in
then back it out a little bit. Just to make sure that
the knob has a little bit of play. And I also want to make sure that it doesn’t stick out the back. And now a final check
to make sure
that gear works. I’m just putting on this gear mount which has got this clever feature
that I don’t actually need to attach the screw.
Just tightening the other knob. It locks secure in place. And this gear seems to be
running fairly well. It’s a bit loud
but it does the job.

100 thoughts on “How to make gears

  1. I have a small plastic gear   there is only a few teeth that are damaged. there is no way to find a replacement. how can I make a replacement. thank you

  2. Can you please make a video on how to make a manual crank sit stand table. With your expertise i am so excited to see it so that i can build my own stand sit table for my laptop and pc. Thank you and You Sir Really Are Amazing thank your for your inspirational shares.

  3. qué tal quisiera saber cómo obtener los planos de las herramientas echas con madera incluyendo los del los engranajes gracias

  4. buenas tardes me llamo nestor de Cuba muy interesante su programa pero es una lástima que no está en español y no lo puedo descargar del móvil para la computadora no me da la opción y estoy muy interesado

  5. I ´d like to know what kind of varnish is used here – seems like a water based one – i´ve seen it being used quite often

  6. All your video are wonderful and instructive. BUT : please have the white subtitles on a dark background ! Thanks 😉

  7. I've never made wooden gears but back when I was an industrial Maintenance Technician, I made metal gears by the paper template and bandsaw method. Sometimes a piece of machinery would break a gear tooth and it could take days to get a replacement. If it wasn't a really high speed or precision gear, or a helical or bevel, I could put it on a xerox machine and make a copy, (actually two copies so I could cut and paste around the broken teeth). Then I cut the teeth on a band saw and hand filed them so they ran smooth. We didn't have a milling machine or the cutters to mill them. The gears were nowhere near precise as the manufactured ones, but they only took a couple of hours to make and would last until replaceements arrived.

  8. YOu ahe more patience than I have cutting out all those teeth.

    Where are you from?

    You sound uk but pronounce bottom and top etc as "bardem" and "tarp" ?

  9. Amazing work sir… can you help me? I was looking for the gear templet different sizes but I couldnt find it! Qould you please send the link at the comment? Thanks and God bless you

  10. I use a 40 watt laser machine to cut out wooden or acrylic gears with. It works perfectly and is much faster and more accurate than a bandsaw. Thicker gears can be made by stacking up several 3/16 layers.

  11. When you put the gear in at 3:24 does the black twisty knob work some sort of lock system that holds the bolt in place? I've been trying this myself (really shoddy job) and I've nearly got it I just cant figure out how to stop the gear spinning the bolt

  12. Your video is so right on something that's difficult you are making it easier to do and simplifying the process thank you for the time and I thought you put into it to make it as straightforward as possible appreciate it thank you I have liked and subscribed to your Channel

  13. I don't know how you get those holes drilled so clean and without the paper template lifting or getting chewed up. No matter how I try my template always gets ruined by drilling and I lose some edges

  14. i saw the wine comment on your website for getting it to work with *nix based systems like mac and linux. i can test that for you. though even if you cant get it to work in wine, you can get it to work using something like vmware or qemu. also if it works in wine, it will work on iphones, ipads or android devices as well since those too are *nix.

    though with as simple as the program is. it could probably be converted to a *nix binary via GCC as the compiler if you had a copy of the source. just compile a separate binary for x86, x86_64, PPC and ARM processor archtypes. make sure it has no requisites for something like directx over opengl, which i doubt it does. the source should be fine to cross compile to any archtype and OS. that would guarantee support for all platforms, mac, pc, linux, microsoft, android, iphone, ipad, all of it would support it. its just a matter of cross compiling it and passing parameters to gcc in the makefile during the compile.

  15. should turn your own screws with a section without threads.Brass rod with tap and die set will take no time.

  16. Anyone know if it would work making these out of hardwood? The ones I want to make will be hand cranked and never very fast. Will wood expansion make them bind?

  17. Got an idea for a hand operated bubble generator for kids, obviously with (at least 5) gears to progressively create more & more bubbles.
    Anyone got any clear perspex? Haha

  18. So if I buy a sheet of plywood, make every size gear I'd ever need, and decorate a workshop wall with them as TEMPLATES ONLY , what sized router bit would I need for the next project this is a trick question, as in, would it save time, of which there is no question

  19. So I want to make my gears out of metal to pull a couple of pulleys however I want to make it much larger than what a printer can print it out as any advice…

  20. And to think that I spent 3 years in an apprenticeship to learn how to develop involute curves and calculate the diametral pitch diameter. You really pay a huge insult to the word gear.

  21. I want to make King of Random's rope maker, but with gears. It's surprisingly hard to find gears to buy at a store. Can't even find them at home depot

  22. The whole reason I came here was because I wanted to see how the actual gears were designed. Seeing the gear generator program disappointed me.

  23. Please don't contribute to the Microsoft monopoly. Please port this to other platforms. Microsoft is a scourge on the planet, and every time people like you create VERY USEFUL tools that run only under Windows you are contributing to that scourge.

    Your work is AMAZING, by the way.

  24. How smart you are scares me a bit. Your demeanor is calm and quiet yet beneath that is a power I cannot comprehend. People we traditionally view as smart – loud, outspoken, good at polishing a perfect image, etc. – are usually in positions of power and are completely different than you. It scares me because the general public, and myself, might overlook your incredible intelligence when meeting you for the first time.

    What is mentally required to assemble what you assemble from start to finish, film it, edit it, and complete everything all the way is absolutely astonishing. It requires enormous emotional stability, inner confidence, love for the craft, focus, clarity, creativity and technical skill.

    Thank you for the videos.

  25. I think that if you drill the hole first in the center and then make a pivot on the band saw with a sliding table, the teeth would come out more uniform as you would not have to align the gear exactly on every tooth.

  26. @Matthias Wandel, not sure if you are still active on youtube. but if you are, had a request: I wanted to make small gears for small dc motors for small toys. do you have any technique for that?

  27. Su vos se parece a el que hace maquinas con canicas que hacem musica creo que es el mismo🤔, quisiera un hacer unos engrane pero con los dientes por dentro se podra🙄

  28. Vegoil guy said you were the gear guru. Glad I watched .it helped alot and will watch more. A big fan!

  29. I love this. And I was thinking… Have you considered making HUGE gears with a Maslow CNC? I think that would be kinda cool and very click-worthy.

  30. I love this. And I was thinking… Have you considered making HUGE gears with a Maslow CNC? I think that would be kinda cool and very click-worthy.

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