My Kinetic Sculptures - A Brief How-To.
Step 1: My Wooden Gears.
My wooden gears were designed on an early CAD program belonging to my neighbor. Unfortunately I don't have the statistics on pitch angles etc., but there are plenty of programs out there that can assist you in the designing of gears, here is an example - http://youtu.be/Hf9NoDT5nDk
My gears range in diameter from 63mm (22 tooth), 121mm (44 tooth), 162mm (60 tooth), and 275mm (105 tooth). The 3 smaller gears have a 22mm center hole for a 22mm(OD) X 8mm(ID) bearing, and the larger gear a 28mm hole for a 28mm(OD) X 15mm(ID) bearing. They are laser cut from 15mm and 12mm plywood board, the cross-grain of the plywood giving the teeth extra strength. The laser cutter does burn the sides, though not enough to effect the performance of the gears. With the burnt edges and my black backboards, I like the look of them. I sand and give each of them 3 coats of clear gloss enamel.
The motors which power my work come from old VCR's, and I will go into detail on those another time. The main image shown here is my very first set of gears, which had a smaller center hole. The other images show the works from the video at various stages of construction.