How to Make Wooden Gears: 4 Steps to Follow

how to make wooden gears

In most of the mechanical systems gears are important component. Simple wooden gears are mostly used for mechanical systems which are low stress as like simple motors and various specialized systems.

Knowing how to make wooden gears can enhance your DIY projects using table saw as a beginner or an advanced DIYer. Read the whole article carefully.

How to Make Wooden Gears – Follow the Following Method

1.Formula and Maths

how to make wooden gears formula

The problem arises when to make efficient gears requires a lot of drawing and mathematical skills as well as the ability to machine complex shapes.

The formula for drawing and making the teeth are all over complicated for the beginners. Following steps can simplify the issue.

  1. Determine the diameter how big or small gear teeth you need, the smaller the teeth the smaller the gear need to be.
  2. All the connecting teeth should have to be the same size. We recommend you to calculate your smallest gear first.

2.Assembling the Supplies

You must have access to a woodworking studio to make wooden gears. You will also need a band saw or jigsaw, brad point drill bits, and a wood rasp. A printer, a smooth shank, and short wood screws also have to be in your access.

You will need to use durable plywood. So we recommend you to use baltic birch plywood. The alternatives can be UHMW plastic, Masonite, or phenolic resin material.

Do not use spruce or fir plywood because they are not strong enough.

Now select a wood generator template online that allows you to modify all the aspects like tooth spacing, number of teeth, number of spokes and more.

After creating the right size of gears, print them off using your printer. Templates generally contains two different sized gears and will allow you  to make size adjustments without messing up the gear ratio.

It is designed for adjusting both large and small gears together. Ensure a smooth rotation by using same size for both sized gears

Generators like this even accept you to animate your design to test how it works.

There are more sophisticated gear templates that are available for download as well.

You can also use paper, pencil, and a protractor to create your own template.

3.Cutting Out the Wood

After done printing your template onto paper, be ready to cut out the template. Do not cut them individually for each gear on paper. Cut the full circumstance out of the circle with the gear’s teeth intact. Do this for both gears.

After cutting the paper templates out, its now time to attach them to the plywood. You’re recommended to use wood glue for best hold.

It is important that the schematic remains intact when you make your cuts.

Dry around an hour for the glue to settle to ensure nothing will mess up.

Now it’s the time to cut out the circumstance using a band saw or a jigsaw. Cutting out a larger one than your design is safe.

Ask for assistance from an experienced woodworker if you are not familiar working these types of power tools,

Generally, work studios contain technicians who are there to assist. Ensure the best use of the resources around you.

Use an awl to make small holes in between each tooth that will guide you when you drill.

No drill holes in between teeth using a 5/16 brad point drill for each one. Don’t worry if holes vary from the template’s design.

If you feel hesitated about using the tool, feel free to take help from someone experienced.

Now you need the best rotation to make the teeth cuts at an angle. Make sure you tilt the table holding to the right when cutting the left lines and  left when cutting the right lines.

Make the final cuts of the teeth using a band saw or a jigsaw. Match the lines according the templates. Remove the outlines using a belt sander and add wood varnish.

4.Finalizing the Gears

Now attach a wooden shank as a handle for the larger gear. Use any piece of spare if you don’t have the shank.

Put the shank on the outer part of the gear of the gear without overlapping into the gears, and then use wood glue for attaching it.

Ensure a secure connection by adding a small wood screw.

Now it’s the time to test the gears ensuring there is not any struggling place in the gear. Remove some material from the groove if the teethes are of unequal size

You’re advised to use your wood filer to file away any resistance you experience as the gears turn.


Hope you’ve learned making gear on a table saw. Modern table saws are very useful to do these DIYs. So, we recommend you to select a woodworking studio that includes table saw.

Do not allow younger boys in carrying your heavy plywood.

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About Robert J. MathenyThis isRobert J. Matheny. I currently work as a junior physiotherapist at a regional health complex based in America. My day starts with my patients who have been suffering from a range of physical conditions, from ailments, tears, strains, stiffness, and other muscular issues. Throughout the daylong association with them, I feel privileged to practice and sharpen my skills, and therefore, learn from everyday experiences. (Site Name) gives me the way to connect with people both from and beyond my clinical visitations. I enjoy writing for people who need advices from someone involved in the real ‘therapy’ job. Wanna know what I have to share? Let’s check out my posts.Description Under A Single Post Being a professional physiotherapist, I cooperate with patients with various physiological issues. It’s my pleasure to be able to share my insights into different health conditions with people. Thus, I hope for a better living for everyone.


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