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Mon 25th Feb 2013

Another page for the Gear Zine...

This time about using mixed 2D and folded tooth gears. For gears with few teeth (in this case, 7) the faces of the teeth need to be curved. These are known as involute gears. I'm using double thickness card to construct 2D involute gears.

I wanted three smaller gears spaced equally around a central gear so there was a bit of geometry involved :-)

By adding the radii of the two gears I knew that the distance between the centre of the larger gear and each of the small gears was 57mm. I planned to make a T shaped base (in red above) Fitting the lower gear and first gear was simple, I just space them by the 57mm.

The other two require a little geometry. I'm spacing the pinions evenly round the central gear, so that is one every 120°

That makes the angle opposite 'a' = 30° so I can work out height 'a' as sine 30° =0.5

0.5 x 57mm = 28.5mm

Length 'b' is calculated the same way but this time with the angle being 60°

sine 60° = 0.8660

0.8660 x  57mm = roughly 49.5mm

With piece the parts laid out, here's how it looks. Again I've made the support piece from the same colour card as well background so it blends in.

...and here it is in a mock up of the zine so far.

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5
Thu 21st Feb 2013

For the next page of the forth coming Gear Zine I need a small drive gear to run against a larger gear. I've decided on a seven tooth gear. The teeth on smaller gears need a more pronounced curved surface than do the teeth on larger gears so I've opted for a gear made from double thickness card where the teeth profiles can be individually cut.

I've gone for the same round pin in a square tube layout as the other gears. The addition of the two green pieces hold the gear square against the axle.

And here's the result. Looking good so far!

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5
Wed 20th Feb 2013

Whilst visiting friends in Bainbridge, North Yorkshire today I can across this mechanical delight. An actual Archimedes Screw actually used to generate electricity. Unfortunately, the delight ends there. I took this photo from the road, as close as I could get to the device. All other accesses were blocked. Piles of wood, no-entry signs, even a string of dead moles! No wonder us Yorkshiremen have a reputation for unfriendliness.
Anyway, the information I could glean: the screw is used to generate electricity. Water falls down the chute turning the screw anti-clockwise as you look at it. The generator is housed in the building at the top. That's it. That's all I could find out. No plaque, no info, no wattages, no carbon saved figure, no access. Very frustrating!
<---edit--->

View Bainbridge in a larger map

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Tue 19th Feb 2013
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Two interlocking gears, one with eleven teeth, one with nineteen teeth. This project is from page one of the gear zine. (coming soon)

Rather than printing out in colour this project is intended to be made using coloured card. You will need three sheets of white card and three sheets of different coloured card. Follow the directions on the download as to which sheet of card matches with which page.

Score all the dotted/dashed lines and then cut out the holes before carefully cutting out the pieces.

Start by constructing the 19 tooth wheel.

Join the two rim pieces together. Make sure that they are accurately aligned. The edges should be one long straight line.

Starting from the end without the taper, glue one of the teeth pieces to the first grey area as shown.

Work your along the rim gluing the lower part of the teeth (between the dotted lines) to the grey areas. Use the black arrows to help with alignment.

When you get to the end of the strip glue the start of the next strip onto the top top of the end of the last strip.

Work your way to the end of the rim. Don't glue down the very last tab.

Roll round and glue together the ends of the rim using the grey areas for alignment.

Complete the rim by gluing the free end of the teeth into place.

Glue the two stiffeners across the centre disks using the grey area and the edge of the square hole for alignment.

Fold round and glue down the stiffeners to make right angled triangle sections. Repeat this process with the other disk.

Thread the axle into place using the grey arrow for alignment.

Glue the two disks back to back with the cross pieces perpendicular to each other.

Fit the centre disk into the wheel rim. Locate the tabs with the edge of the rim and glue them down.

Roll the pin tightly so that it just fits into the axle tube. Glue the end down.

Thread the pin into place to complete the gear wheel.

Repeat this process to make the smaller gear.

Assemble the support box.

Glue the three legs to the grey areas, two on one side, one on the other.

Complete the gear by carefully threading the pins through the holes in the box and meshing the two gears together.

Here is the top view.

In the photography for the gear zine I used a support box made from the same color card as the backing card so as to emphasise the gears.

Turn one gear the the other gear is turned by the interlocking teeth. Notice that the gears turn in opposite directions. The larger gear turns at 11/19 the speed of the smaller gear.

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With thanks to Urmish who pointed out that the large gear has nineteen teeth, not twenty one as I had originally stated. Oops!

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Mon 18th Feb 2013

So here's the plan...

A zine in the same format as previous zines, so that'd be six pages plus front and back cover. Each page featuring gear based facts including perhaps worm gears, bevel gears as well as gear trains and the standard gears featured here.

...and I must say that this gear is silky smooth in its operation!

The card used in the base and the gear walls is multi-coloured 210gsm printer card from Ryman's in the UK. Very nice it is too!

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2
Sun 17th Feb 2013

I'm in the process of putting together another Zine, this time on the subject of gears. I thought it would be fun to use photographs of paper gears as illustrations. It has turned out to be instructive as well :-)

This eleven tooth prototype has problems with the axle moving from side to side. As well as addressing this problem I would also like to try out using a circular axle rather than the square section ones I have used up until now. Square section tubes have the advantage of being easy to assemble accurately and easy to fit into place. They have the disadvantage that a square peg in a round hole doesn't make for a good fit.

Starting with a ring and eleven teeth...

I added triangular section pieces, to each face adjacent to the square hole. The two faces have the stiffeners running at 90ª to each other. One piece takes care of front to back movement, the other takes care of side to side. I've also made the hole slightly smaller with the square section tube now only 6mm on a side.

Here, the centre piece is fitted into place.

Old vs new.

And to complete the gear, I've threaded a tight fitting rolled tube through the square tube.

Here, fitted through a 6mm diameter hole, the gear runs smoothly with very little play.

Next to mesh it up with this 21 tooth gear, then on to photography.

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Sat 16th Feb 2013

Congratulations to the Coffee Kitchen in Cockermouth, our favourite local coffee shop! They won, Best Newcomer in the recent Cumbria Life Awards.

In celebration I've highlighted my coffee themed paper projects below.

 Too Much Coffee, Paper Animation Kit Make Your Own Caffeine Molecule Hot Choc Sprinkles (Works on coffee too!)

Hot Choc Sprinkles is free for everyone to download, the other two are free for all members.

Have fun!

Right, I'm off for a coffee :-)

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Thu 7th Feb 2013
£2.50
See the Membership page for more details.

A pop up Elephant to make for your Valentine. Fold the elephant flat and slip it into a greeting card. When the card is opened the elephant pops out to the delight for your #truelove.

The project comes in three colour schemes and a mono version. Print out the parts of the version you choose onto thin card. (230 micron / 67lb) Note that the last page of the colour projects is coloured on both sides. Print out one side, flip the card over, return it to the printer and print out the back.

Score all the dotted and dashed lines then cut out the holes. Exercise the creases to ensure they fold easily.

Glue the grey areas of the head and body together lining them up as accurately as possible.

Fold the head and body round, glue the hooked tabs face to face to make double thickness card.

Glue together the sides that are opposite the hooked tabs. This will hold the box in shape but still allow you to access the hooked tabs to fit the elastic band in the next step.

Select a long thin elastic band.

Hook one end over the smaller hooked tab, thread it through the hole in the box and hook it onto the other tab.

Close the other sides by gluing them together.

The tusks are double thickness card. Make them by folding the card in half and gluing it together then carefully cutting out the pieces.

Glue on the tusks as shown so that their edge lines up with the diagonal edge of the side piece.

Glue the ear tab in place so that it is vertical and central.

Glue the face to the front of the box.

Glue the legs to the side of the box. Make sure that the toe nails are to the front of the foot.

Finish off the model by gluing the heart to the trunk as shown.

That's it! Fold the model flat, slip it into a Valentine card and send it to your one true love.

Make yourself a herd!

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Wed 6th Feb 2013

I thought that the popup elephant I made the other day would make a nice Valentine project - I hope that #truelove agrees!

Looking at the original I thought it might be better with a head not made from a cube but slightly shortened front to back. After a little experimentation I came up with this prototype.

Which then developed into this project.

And it still squashes down nicely ready to pop up!

Do you like the bokeh in the first picture? 35mm f/1.8 lens - looking good!

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Sat 2nd Feb 2013

Friend of the website and prolific modifier Michael42er has created a new paper animation, this time combining the Vertical Pendulum and parts from the Pneumatic Giraffe

Nice work Michael!

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