Step 6: Cutting The Gears
Now comes time to put the hard design process to the test. Cutting the gears. After printing out the full size drawings, I cut them out and glued them to the wood. A spray adhesive works great. I use 3M Super77, and it dries fairly quick. At least within a few minutes after gluing, I'm ready to start cutting without it peeling off.
I drill all the holes first. It's easier to handle a full size board with the drill press than trying to clamp a gear blank that's only 1.5 inches in diameter without splitting it. Also, if something goes wrong, you haven't wasted all that time cutting it out just to have the board split.
After drilling the holes, I cut the gears out around the outside diameter, then I start cutting the teeth.