I have updated my method
for making wooden gears to make it better. The new E-book contains 52 pages, and lots of illustrations to cover the
technique using table saw, scroll saw, and now the router. This PDF file will most definitely save you a lot of time
and frustration over the other method of sawing and sanding around a pattern. It describes how to make spur gears, herringbone
gears, helical gears, and gear racks. It is easy to get good and consistent results. If you have specific questions
about it, then send me an email to the address at the bottom of this page.
The Gear making technique is available as an instant download ebook PDF file by clicking the button below.
By clicking this button, you will be taken to Paypal to confirm. You will then be sent instructions to download
the files. If you do not have a Paypal account you can still use a credit card for the purchase through Paypal.
If you do not have or want to use a credit card I will also accept money orders - email me for mailing address. The
price for the technique is $24.99
The video above demonstrates how easy it is to cut very precise gear teeth
that operate very smoothly. Each tooth first gets a "rough" pass to remove the majority of the material from
the area between the teeth, then lighter cuts are made to each side of the notch to get a smoother finish, and to make the
teeth the correct thickness along the pitch circle. It is also possible to re-work the tooth profile of a gear made
with a different method (involute profile only) to eliminate binding, or to add more backlash for clearance. The bit
used in this video is a 1/8" diameter 9/16" cut length down spiral solid carbide bit spinning in a Bosch Colt router.
Much better than sanding!
Does It Work?
technique utilizes a simple principle illustrated below to generate gear teeth instead of sawing or sanding to a line on a
paper pattern using the old method. This makes the task of cutting gears much easier, less tiring, and more accurate
than other methods, it also lets you make helical gears which are not possible with the old method. You can make gears
with any number of teeth . Chances are that you already have all the tools you will need: drill press, bench-top disc
sander, and either a tablesaw, scroll saw with spiral blade (spiral blades are not available for saws requiring pin-end blades),
or router (spur gears only with router). You can use ordinary table saw blades or straight router bits. The simplicity
of the technique is what makes it work so good. The only sanding you will need to do is to lightly de-burr the edges
after the teeth are cut or shaved to perfection. You will get a perfect profile even if your vision is not very good
because the cut does not rely on cutting to a line visually, the profile is generated as shown in the drawing below. Small
gears are not a problem to cut safely because they are not held by your fingers while being cut. Very little of the
blade is exposed and I believe this technique is safer than making a rip cut on a table saw.
purchase the technique, I will include an Excel spreadsheet calculator that calculates all the needed dimensions using these
input parameters: number of teeth, diametral pitch, pressure angle, and helix angle if you want helical gears. This
spreadsheet can be used with Google Documents (free with Google account) if you do not have Excel. I will also include
a guide for elliptical gears as seen in the video. You will also get future updates at no charge as I make improvements
and add new capabilities, technical support, and sample guides (pdf format). You will also get access to my videos that
demonstrate the technique in action on router, table saw and scroll saw.
This technique is very intuitive once you see how it works.
There is no need for expensive cnc routers or lasers or any computer-controlled tools. If you have a scrollsaw or tablesaw,
the ability to cut accurately sized circles from plywood, and a computer - then you can cut gears. You won't find this
technique anywhere else, I have looked thoroughly and know it is my own original idea. If you have any questions about it,
please feel free to send an email to my address at the bottom of this page.
Steve Fleury used my gear-making technique to make the birch plywood gears in his sculpture #22 shown below.
He used a router table with a 1/4 inch diameter straight bit to cut the teeth. The largest gear is 13.875 inches in
Mate the way you have explained
how the gear generator works and how to change the settings was just the best.
I can only say “Thank
you so very much”
Everything was just so simple and the way you explained it to me. I was playing
all day with it and my brain was hurting from the applications that I could do with the knowledge that you have passed on
You are right when you said that all of a sudden it will just click in my head and you were 100% correct.
I have printed up about 10 gears (just for fun) but the best part was when I made two gears on the table saw.
To see the gears work without any jamming of the gears it was just artwork.
I cut four spokes and stuck some
ice cream sticks on the side and then turned the compressor on and watched the gears that I had just made turn beautifully
as the air pressure turned the gears.
Again thank you so very much
Your friend, Shane
"A simple but fantastic method of cutting gears. Well worth the investment. I was feeling a bit daunted by trying
to make wooden gear clocks again. But your method reduces the cutting time by 80%. A lot of people will be getting presents
and house warming gifts. Thank you."
you for your email. I did get everything I needed. I am an amateur machinist and been at it for 38 years.
My calling is that of a Pastor but I make metal chips in my machine shop bus (66 passenger full of machine tools). I
also do woodworking but put myself in the wood butchery class there. I've made many metal spur gears and always
wanted to cut helical gears but that takes a universal table on your horiz. mill or a very exotic attachment that costs more
than my mill! However, your method of cutting helicals in wood will be just as thrilling to do and for making toys for
the grandkids it will be a winner. You've probably been told you're a genius before, well let me pile on as
well! Thanks for making this information available at a very reasonable price. May you prosper as your soul prospers!
Mike Fendley, Stratford, Iowa
Camp Lejeune, North Carolina. I got my
degree in physics and I love the engineering behind the gears, you can bet I will be finding a huge number of usesfor them, both for decorating (wood blinds, etc) and for functionality (I'm thinking windmill and other power generating
applications. Sky's the limit!Wonderful achievement, thank you! Jared