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this instructable is for the steampunkers out there needing brass gears for projects, not acurate or functioning, purely decorative. My next gear proj...
google search gear images, found adding "silhouette" to my search found more stensil worthy images.
i use arcsoft photo studio5 for most of my images, or paint works too. then place image in your photoshop or paint, crop and print to the size you wa...
i found some 2inch by quarter inch bar stock at home depot, and cut it at 2 inches for a square piece to work with.
moving toward "stock removal" i began drilling numerous holes along the inside edge of the stensil where i wanted to remove to create the gear spokes....
after drilling series of 1/16ths holes as closely as i could, i ground a standard screwdriver bit into a chisel. laying the brass stock on the flat an...
time to drill the teeeth of your gear, not the ones in your mouth. same drill bit as used b4 1/16th , with any drilling device you wanna use. previou...
at this stage its time to cut away everything that is OUTSIDE of the gear stensil. clamped in the vise i cut the corners away with the hacksaw as clos...
clamping the round chunk O brass i have created in my vise, i hack saw slots frm the outside to the holes i previously drilled for the gear teeth. wit...
filing the tooth slots are done in stages, sawing slits opening up the 1/16th holes, then using a flat needle file to enlarge the slots, and finishing...
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