simple wooden sprocket without cnc machines

I made this instructable because I needed a way to drive multiple axles in sync for another instructable I am making. Unlike some makers I have no access to any CNC machines and due to that, I cannot build custom parts easily. One thing I am fortunate to have though is a fairly nice wood working shop, not that you need a very nice one for this project. I have attached the link to the design in the 123D library for all those CNCers out there, but for everyone else you can make this with some simple tools. This sprocket can be used for mechanical purposes, or it can be used for art and decoration.

design:http://www.123dapp.com/123D-3D-Model/sprocket/602414

PLEASE VOTE FOR ME!

tools/materials needed:

-a hand saw (or a table saw that can cut 45 degrees)

-a drill (I used a drill press, but a drill will work)

-a 3/4 inch drill bit

-wood thicker than 1/8 in (plywood will splinter easily)

-an accurate ruler or measuring tape

-a clamp or two

-a metal file or sand paper

-SAFETY FIRST! safety glasses

lets get started!

Step 1: Squaring

First, you need to cut a square out of the wood. This square should be 2.5 in x 2.5 in. Make sure it is as close as possible to being right on. The problem with this whole project is that with an octagon, in order to make one with one inch sides from a square you need the dimensions to be 1+(2/(sqrt2)) which is unfortunate because nobody makes 1/sqrt2 rulers. Fortunately 1/sqrt2=.707106... which is very close to 3/4 or even closer to 11/16. I used 3/4 which is why the square is 2.5.

Comments

[useraaaaa]

dill holes,
only after that remove corners

[avisser]

Excellent! I like your idea of using an octagon to make the 'teeth' ends have the right shape.

[rimar2000]

Very interesting, thanks for the idea.

[rickharris]

Neat