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How to Make a Wood Helical Gear

While gears come in many varieties, the helical gear has been proven to be one of the most effective and well-performing. What sets helical gears apart from the rest is their diagonal teeth pattern, which allows for smooth contact between gears and noise reduction. As a result, they can be found in almost every modern car transmission. While transmission gears are manufactured from special alloys and require precise machining to manufacture, helical gears being used for demonstration and modeling purposes can be made from wood and simple materials.

Things You'll Need

1/16-inch hardwood sheets
Jigsaw
Electric drill
Thin flat wood file
Sandpaper
Wood glue
Paintbrush
Clamps
Wood finish
Wood filler
Cardstock
Pencil
Marker
Ruler
Scissors
Drafting compass

Instructions

- 1
  Decide on a diameter for the gear face. Draw a circle of the same diameter on a sheet of cardstock with a drafting compass, ensuring that the circle is perfectly round. Mark the center with a marker.
- 2
  Cut out a small section of cardstock and draw the outline of a gear tooth. Draw it so the thickness is relatively consistent and thin and it tapers off slightly on one end. Cut out the tooth layout.
- 3
  Place the base of the tooth layout on the outer edge of the circle from step one, with the tapered edge facing outward. Trace around the layout so the tooth and circle connect on paper. Repeat this process for the entire circumference of the circle until the shape of a gear is formed, keeping a consistent gap between the teeth.
- 4
  Cut a piece of 1/16-inch hardwood sheet with a jigsaw. Keep its length and width slightly larger than the total diameter of the gear outline from step three. Do this for about eight other sheets.
- 5
  Cut out the gear outline, and place it over one of the 1/16-inch hardwood sheets. Trace the gear outline onto the wood sheet with a pencil and set the outline aside. Go over the outline with a marker.
- 6
  Apply glue lightly along the perimeter of each face of the wood sheets, so most of the face is free of glue. Stack the pieces together with the gear outline on top, clamp them together and let dry. The glue is only temporary and will keep the pieces together while being cut.
- 7
  Cut the stacked pieces along the gear outline with a jigsaw, being extra careful and precise around the teeth. Lightly sand the teeth of the stack, making sure they are all equal in size. Disassemble the stack, and ensure the gear faces are identical.
- 8
  Apply an even coat of glue to the face of each gear with a paintbrush and stack them together so the teeth form a diagonal pattern. Clamp the stack firmly together with clamps and let it dry.
- 9
  Smooth out the gear teeth by apply wood filler to the small ledges created by the diagonal pattern. File down the gaps between the teeth with a wood file while maintaining the diagonal pattern.
- 10
  Drill a hole through the center of the gear with an electric drill. The hole should have the same diameter as the axle. Apply two coats of wood finish to the gear, lightly sanding the exterior after each coat has dried.

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