Instructables

Gears from craft foam

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Make some sturdy lightweight gears out of craft foam!
 
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Step 2: Cut the gear shapes out

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This particular pattern has a hole sized so that if the big gear is approximately 3 inches wide, the hole just fits a size 10 machine screw which can serve as the axle

cut the gear shapes out of both craft foam and posterboard

A craft cutter is probably essential for this.

I've attached a Make the Cut project in case you have one

Step 3: To the dentist

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If some of the gear teeth have little anomalies after going through the cutter, you can trim those off at any time

Step 4: Glue the gear layers

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coat the posterboard gear with a fine layer of glue

lay the foam gear over it and slide it around until the gear teeth line up perfectly


lay those flat and let them dry

Step 5: Glue the gear layers together

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apply glue to the foam surface of  a gear layer

stack them up about 6 deep, being careful to line up the teeth perfectly straight

Step 6: Clamp and allow to dry

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Make sure the glued layers are all lined up perfectly.

Apply clamps if you have them.

If you picked up some of those awesome clamps from Dollar Tree they have a nice feature that you can remove their little crimp pads off their ends. This makes them just about perfect for holding the gear teeth in alignment while the layers dry.

Allow the gear to dry overnight


Step 7: Yay gears!

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Now to put them to work!