It's vital to use good plywood for the gears. The method I use to make the gears for the box joint jig is the same as for the gears for the wooden router lift, but I'll focus on the ones for the box joint jig in this article. You can click on any image in this article to get a larger view. So I figured I'd cover the topic of gear making in a bit more detail. How to make wooden gears This page also available in Spanish Some people are intimidated at the prospect of making their own wooden gears for the screw advance box joint jig. As an improvement over the majority of other freely available scripts and utilities it fully accounts for undercuts. Rainer Hessmer An open source, browser based utility for calculating and drawing involute spur gears. Rack and pinion gearing You can also generate rack and pinion gears. The gear tooth generation is not perfect. This gear template generator generates shapes for involute spur gears. Some notes about gear design and this gear template generator This template generator is intended for generating paper templates for cutting low precision gears from plywood, phenolic, or other suitable materials with a band saw.
You can still access the old Flash based version Getting the printout to scale correctly Different browsers print at different scales depending on browser type and printer configuration. This is the new version (as of September 2015). Even cheap ink jet printers print very scale accurate but Not all laser printers are accurate. I recommend printing the gears with an ink jet printer. This free online gear template generator is designed for making scale accurate paper gear templates which you can glue onto wood and then cut out with a bandsaw.
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