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In order to create well presented gears, the teeth must be well spaced. Modern machinery is very capable of reaching very precise measurements. Yet, if one is using very thin-bodied gears, then matching one tooth to the next will prove difficult if there are no guides available. My solution is simple and effective. A 1/4" homemade plywood guide holds one taper to the next in position. The following tutorial demonstrates the steps to making a customizable homemade plywood guide.
Using wood for gears is rather simple. Even more so using the old fashioned wood gear method with hand tools. But using wood has the disadvantage that if you are trying to produce many in quantity, then the expense becomes prohibitive. Homemade plywood allows us to use wood of a type and color (as with woods other than Baltic Birch) to match the clock. Even if the dimension is exact, it is also far cheaper than hand making gears.
You can make your own custom wood gear template with this free online calculation. Or, you can make a custom wooden pattern that you could then use to make your own gear templates that will reproduce any wood gear perfectly. The process takes just a few minutes to complete. d2c66b5586