One of the most difficult and yet common mechanical systems is a gear train. A great way to transmit mechanical power from one place to another or to increase or decrease power (torque) or increase or decrease the speed of something.
The problems are always that to make efficient gears needs quite a lot of drawing and mathematical skill as well as the ability to machine complex shapes.
For a lot of amateur work it isn't necessary to have maximum efficiency and therefore we can get away with a much easier to make, even with hand tools, system.
A gear is basically a series of teeth on a wheel.
provides a very good explanation of how gears work and how to work out gear ratios.
Step 1: Formula and Maths (the bad news)
Formula for drawing and making gear teeth are all over the web BUT they seem, to the beginner, very complicated.
So I decided to simplify the issue and it works very well at both large scale and small scale. At small scale it works best with machine cutting with laser cutters for example when very small gears can successfully be made this way.
Step 3: The easy way
1. the shape of the teeth is simplified to be half a circle