Woodworker Matt Wandel has a tool on his site for designing your own “low precision” gears (i.e. wood, phenolic plastic, etc) and printing them out onto paper templates for cutting. You can define two gears (with tooth size, count, angle) and watch them interact. The site also includes a brief tutorial on how to cut out the gears from the templates.

Interactive gear template generator – Link

Gareth Branwyn

Gareth Branwyn

Gareth Branwyn is a freelance writer and the former Editorial Director of Maker Media. He is the author or editor of over a dozen books on technology, DIY, and geek culture. He is currently a contributor to Boing Boing, Wink Books, and Wink Fun. And he has a new best-of writing collection and “lazy person’s memoir,” called Borg Like Me.

  • chroma

    SDP-SI has downloadable DXF format CAD files of various spur gears. I’ve used these in the past to make custom gears.