Template to Cut Gear Teeth on Plywood? - Router Forums
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post #1 of 15 (permalink) Old 09-26-2020, 04:17 AM Thread Starter
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Default Template to Cut Gear Teeth on Plywood?

I’m making a wooden clock and of course I will have tons of gear teeth to cut which I never done before. The gears size which all will be made from 1/4” or 1/2” plywood vary from 8” to 1” OD.

I will have a pattern for each gear which I will glue to my plywood and have no problem rough cutting the teeth with my bandsaw / router / sander but I can see a problem when the time comes to do the trimming of each tooth to achieve the right curve and make them all identical (some teeth are straight and some have a slight curve).

Has anyone developed some kind of a template for this kind of work or can suggest a way to achieve good results?
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post #2 of 15 (permalink) Old 09-26-2020, 05:00 AM
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scroll saw for machine...
rough cut and use an Olson plain end scroll saw file #42100 for finessing and clean up...
fret saw for by hand...
make the teeth as inserts...

do you have a lathe???

find - wood gear cutting by Ron Walters
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post #3 of 15 (permalink) Old 09-26-2020, 06:15 AM Thread Starter
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As mentioned, I have no problem cutting the teeth.

I’m looking for a way to have the teeth identical after the rough cut like you would have done if you were using a CNC. I have an idea of using a template and use my router to follow the template to trim each tooth so all teeth will be identical. But this is just an idea right now and working to see how I can implement this idea.

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post #4 of 15 (permalink) Old 09-26-2020, 06:17 AM
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can you find steel gears to use as templates???

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post #5 of 15 (permalink) Old 09-26-2020, 06:21 AM
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these links might foster ideas...
an indexer will be the most valuable tool...

https://www.star-su.com/cutting-tool...cutting-tools/
https://www.cnclathing.com/guide/gea...ing-cnclathing
https://capitalgeartools.com/milling-cutters/

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post #6 of 15 (permalink) Old 09-26-2020, 09:26 AM
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There is an add-on to Fusion 360 that will generate gears for you. Works pretty good.

Here are some of the ones I've cut using F360 for the CAD/CAM and cut on my CNC -
Template to Cut Gear Teeth on Plywood?-002-3-gear-custom-set.jpg

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post #7 of 15 (permalink) Old 09-26-2020, 10:02 AM
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Quote:
Originally Posted by kolias View Post
As mentioned, I have no problem cutting the teeth.

I’m looking for a way to have the teeth identical after the rough cut like you would have done if you were using a CNC. I have an idea of using a template and use my router to follow the template to trim each tooth so all teeth will be identical. But this is just an idea right now and working to see how I can implement this idea.
That's how I do my stuff. Use 1/2" plywood, spend time, make one of whatever perfect. Then glue that one onto a piece of 1/2" plywood, rout it. That give me a 1" thick master - easier to hold on to. I drill pilot holes in the master, use those and tack the master to the rough cut piece, rout, and have a finished piece. Repeat until you have all of those particular pieces you want. Repeat for each different size or pattern. Works for me.

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post #8 of 15 (permalink) Old 09-26-2020, 05:47 PM
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https://www.woodgears.ca/gear_cutting/template.html
The number of teeth is variable and one can even create templates for rack and pinion systems.
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post #9 of 15 (permalink) Old 09-26-2020, 07:54 PM Thread Starter
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Thank you all for the ideas, now it’s time for me to use what I learned and along with my ideas try to find out the best way to cut my first gear. Obviously I will have to experiment on some scraps first and I will post the results
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post #10 of 15 (permalink) Old 09-26-2020, 08:14 PM
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Quote:
Originally Posted by kolias View Post
Thank you all for the ideas, now it’s time for me to use what I learned and along with my ideas try to find out the best way to cut my first gear. Obviously I will have to experiment on some scraps first and I will post the results


Here's a technique for using a table saw...just another option...but it seems to add the rounded edge for matching gear teeth...


Good luck

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